Hydraulic Components Repair TCLO38‘Caterpillar Service Technician Module Hydraulic Components Repair Published by Catespillar of Ausiraia Pty Lid. 4 Caterpillar Drive Tullamarine Victoria Australia 3043 Version 4.1, 2007 ‘Copyright ©2007 Caterpillar of Australia Pry Lid Melbourne, Australia. Al fights reserved. Rlepradustion of any part of this wack without the pecmizsion ofthe ‘eopynight owner is unlawiul. Flequanis for permiazion o* further information must be addreazed ta the Caterpillar Learning Manage, Auztralis, ‘This subject materials is insued by Caterpillar of Australia Pty Lid. on the understanding that: ‘Caterpillar of Australia Pty Lid its oMcinls, author(2), oF any other pemona invalved in the: preparation of thiz publication expreazly diaclaim all or ary contractual, tortious, at other farm ‘ol fiabilty to ary person [purchaser of this publication or nof) in respect ofthe publication and ‘any consequence alsing from its use. inchucing any omission made by any person in refance upon the whole or any part of the contents of this publication. ‘Caberpillar of Australia Pty Lid. expressly disclaims all and any liability te any perscn in reapect of anything and of the consequences of anything done or omitted to be dane by any ‘such person in miance, whether whole or pactial, upon the whole or ary part of the cortents ‘ofthis subject mazeria, ‘Acknowledgements Aspecial thanks to the Caterzillar Family for their contsibution in reviewing the curcula for ‘this program, in particular: = Cusempillar engineers and instructors Dealer engineers and instructors = Caterpillar institutes.Table of Contents INCLUDED IN THIS MODULE: Module Outline Document ....cccccccccssesssssse ldMooute Outune Document IncLupeD In THis SecTION: Learning Outcome Details and Module Information5. Asfacenoes: - TCL038 Facifimor Guide - Relevant manufacturer's specifications - SEBFS0G0 Vane Type Hydraulic Pumps: - SEBF80S2 Piston Pumps and Mators - SEBFSO72 Inspection and Salvage of Hydraulic Cylinder Components: - SEBF8073 Hydraulic Gear Pumps and Motors (Gear Pumps} - SEDPRISE Guide to Cleaning 6. Heoommended maximum studentiieacher ratio: = Glazaroom — 18:1 = Workshop - 1 7. Resources for Student — TCLOSS Shedent Guide (one for each student) - TCLOIS Activity Workbook [one foreach student) - Relevant manufacturers specifications Revisi Nil Assorsment Thin is a practical module. Leaming Outcomes should be assessed using formative and summative practical assessments. Attainment of the student performance af a hands-on level is achieved by the use of practical activities aligned with marking guides.LEARNING OUTCOME 1: — Mentity the procedures for disassembly, apection. assembly and esting of hydraulic At the completion of this laaming outcome, students should be able to: 1.1 identify the procedures for disassembly, inspection, assembly and testing of a gear type hydraulic pumpimotor 1.2 Identify the procedures for disassembly, inspection, assembly and testing of a variable displacement piston type hydrauls pumpimotor 1.4. identify the procedures for disassembly, inspection, assembly and testing of vane type hydraulic pump/motor Attainment of the periormance is confirmed i the student can: 141 Identify the procedures for disassembly, inspection, assembly and testing of a gear type hydraulic pumpimotor 1a Componenss, ‘ULL Single section pumps ‘ULL2 Single weuiion pump — bi-rectionall ‘13 Double section pump 112 Disassembly 1021 Mounting 1122 As per specifications 4143 Inapection of components iat Cleaning 4132 Mounting face 1033 Seallbore nas Bushing 10135 Gear tack - Wear - Bure = Cmcking 1138 Seal groove 1097 Threaded holes 1138 Dowel holes: ‘tag Casting Banges 411910 Gear body ‘LAY Selymge procedures — seal bore inate Gear shatsaa au wa saaa sae sa43 vga sas = Cleaning = Sel shait ares = Spline = Bearing aren = Tooth face = Tooth prfile = Shit Presaure face Coupling ‘sri Shak end cower Goarheuning Beasing cartier Pertend cower 115 Start up and test procedure LLB Troubleshooting 1.2 Identify the procedures for disassembly, inspection, assembly and ‘testing of a variable displacement piston type hydraulic pumpimotor: 124 Component identification 122 Disassembly 123.0 saan sea y23.01214 Contra plane stop 41241 As per specifications 125 Stat up and test procedes 12 Identify the procedures for disassembly, inspection, assembly and testing of a vane type bydraulic pumplmotor: 133, Componens: 132, Disassembly 1521 Single vane pump 1322 Double wane pump 19 mepocion f compen (Cleaning “Touch lapping procedure Saivage Power lpring Touch Igpping (Grinding Cam cing Foto ‘Vane and vane iret ‘Shaft PE REEEEGGE 1241 Single vane pump 1242 Double vane pump 4183 hs per specications 135 Startup ond test proceduresLearNinG OurcomE 2: Identity tha procedures for disassembly, inspection, assambly and testing of a hydraulic actuator. At the completion of this leaming outcome, students should be able to: 24 Identity the procedures for disassembly, inspection, assembly and testing of a hydraulic actuator. Attainment of the performance is confirmed if the student can: 21 Identity the procedures for disassembly, inspection, sssembly and ‘testing of a hydraulic actuator: 211 Companents 212 Disassembly Biz Cleaning prior to disassembly 2122 As per specifications 213 Inspection of components 21341 Cleaning procedume 2132 Housing tube and ends Baa Bore — Somtches — Wear — Fust — Scoring damage 2134 Aetubing 2135 Ahoning 2136 Oversize honing 2137 Seal aclection 2138 Oversize idensfioation 2130 Cylinder azeembly chamber dimensions: 24380 Cylinder head nomenclature 21301 Head inspection 24342 Head wear sing installation isa Piston and nut 24344 Cylinder rod nomenclaturea4 - Scratches - Scoms Light piting om the chrome - Surface nicks — Heawy pitting Chrome plating on the red surface = Polishing = Bent rod = Damagedibroken rod — Flod ends - Eye measurement = Bent rod = Flerodding ‘Assembly 2141 Aa per specifications Test procedures 2151 Double acting cylinder 2152 Twoand three singe ejection cylinder 2153 Foursinge Ejection CylinderLEARNING OUTCOME 3: — identify tha procedures for disassembly, ‘inspection, assambly and testing of a hydraulic irectional contral valve. At the completion of this leaming outcome, students should be able to: 1 Identify the procedures for disassembly. inspection, assembly and testing of ahydroulic directional control valve. Attainment of the performance is confimmed if the student can: 41 Identify the procedures for disassembly, inspection, assembly and testing of a hydraulic directional control valve: 11 Disassembly 314.1 Clesning before disassembly ‘112 Asper specifications 5412 Inspection of components, 33121 Cleaning prior to mspection atz2 Housing S425 Fitings Sid Plugs 3125 | Springs a1z O-ings 127 Check valves: 3128 Spool assemblics 2129 Line relief valves (if fined) 31250 Control waives: 201 Main rebel valve 31212 Priority wahe (il fitted) 515 Assembly 3131 Asper specificationsLeaawinc Outcome 4: — Disassemble and 2ssomble a hydraulic pamp. NOTE: Thisis a practical Learning Outcome. This module does not include an underpinning knowledge test. Delivery of a demcnssration lesson by the Facifiator must coour belore shedents attempt this Leeming Outoame. Given one of the following types of pumps: = Gear type pump = Vane type pump = Variable Displacement Piston pump. At the end of this leaming outcome, students should be able to: = State and follow the safety precautions that must be observed to prevent personal injury of damage to equipment = Disassembly, inapection and assembly procedures are idenslied according to manufactures's specifications = Tasks include: - Exemal visual checks, Disassembly in accordance with manufacturer's specifications = Tasks are completed — Without causing damage to components or equipment = Using appropriate tooling, techniques and materials = According to industryfenterptize guidelines, procedures and policies — Using and interpreting corect information from the manufacturer's specifications.LEARNING QuTCOME 5: — Disassemble and assemble a hydraulic actuator. NOTE: This iz a practical Leaming Quicame. This module does not inchide an underpinning knowledge test. Delivery of a demonstration lesson by the Facilitator must occur belore students attempt this Leaming Ouicame. At the end of this leaming outcome, students should be able to. ‘Stmie and follow the safety precautions that must be obserwed to prevent personal inqury or damage to equipment. Disassembly, ispection and assembly procedures are identified accomding to manulacturer's specifications Tasdes inclisde: = External visual checks - Disassembly in accordance with manufacturer's specifications = Assembly in accosdance with manuincturer's specifications - Functional test. Appropeinte workshop documentation is campleted. Tasks are completed: = Without causing damage 10 components or equipment = Using approprisis tealing, techriques and materials - According to industrylenterprise guidelines, procedures: and policies = Using and intespreting correct information from the manufacturer's ‘specifications.Learwinc Qurcome G6: Disassemble and assemble a hydraulic Directional Control Valve. NOTE: Thisis a Practical Leaming Outcome. This module does not include an underpinning knowledge test. Delivery of a demonstration leceon by the Facilitator must ocour before students attempt this Leeming Outcome. At the end of this Ieaming outcome, students should be able to: = State and follow the safety precautions thal musi be observed lo prevent personal injury or damage to equipment. = Disassembly, inspection and assembly procedures are identified according to manufacturer's specifications = Tasks are completing = Without causing damage 1 components or equipment Using appropriate tooling, techniques and materials = Accomding to industwenterpeise guidelines, procedures and policies Using and interpreting correct information fromm the manufacturer's specifications.ve | | Hyprauuic Pumps INCLUDED IN THIS Topic: Goar Pump (Pilot) — Disassemble. Gear Pump (Auailiary| —Disassembl Inspection of Components. ——_____ ‘Single Vano Purnp Assembly Procedura. Double Vane Pump Assembly Procedure_GEAR TYPE HYDRAULIC PUMPS This section will familiarize you with disassembiylassembly of single and mutiple section gear pumps and motors. It also shows visual examples of wom hydraulic gear pump and motor parts, specifically it shows ilustrations of components that may of may not be used again with/without reconditioning operations. Most of the visuals are of pumps and not motors. While pumps have a different purpose than motors, the disassembly procedures are similar unless specified differently by the manufacture. Cleanliness is the primary means of ensuring satisiactory life, either on new or CAUTIONS AND SPECIAL NOTES: ‘Use caution when gripping parts in.a vice to avaid damage to machined surfaces (Certain cleaning solvents are flammable. Do at allow sources of ignition in the area when using cleaning sclverts. ‘Use exireme caution when working with hydraulic fiid under pressure, hydraulic Bui under preceure can have sufficient force to penetrate your ekin, ‘causing serious injury. WARNING: Personal injury can resub from hydraulic oil pressure and hot oil. Hydraulic oil [pressure con remain in the hydraulic system after the engine hasbeen stopped. ‘Serious injury can be caused if this pressure is not released begore any service is done on the hrydrauic system. Make sure all of the attachments have been lowered, wiliis cool before removing any components or lines. Flemave the wil filer ‘oop only when the engine is stopped, and the filer cap is cool enough to touch ‘with your bare hand.Part Identification ‘Single Section Gear Pump Uni-Directional ‘Figure 1 shows a Single Section Gear Pump UniDirectionalFigure Figure 2 shows 3 Bi-directional gear pump. it contain many of the same parts as ‘uni-directional gear pumps, but notice thet they contain isalabon plates on both sides and O-rings instead of the saaing strips. This permits esch side ofthe um to act 25 & low pressure and high pressure side,‘Figure 5 shows the components of a Double Section Gear Pump. The O-rng {pot chow) relocated on the bac of he flange aeDISASSEM! NOTE: ‘Care must be taken 1o ensure thal fluids are contained during performance at inspecton, maintenance, sesting. adjusting and repair of the product. Be prepared to collect the Suid with suitable containers before opening any compartment or disassembling any component ccnasining luda. Diapose of al ude eccording to local requingans nd mandates Alemove pumpimotor from the equipment to be serviced. Use the manufacturer 1 removel procedure. Use all the correct tooling and safety procedures as specified by the manufacturer. Mount the pump in a secure vios or mounting table (shaft end down} (Figure 4, left). With # sharp metal scribing tool, grease pencil or magic marker, scribe a line down the pump trom port end cover to shal end cover. This line will be used for realigning components during reassembly. lemove the caps screws and washers on single units or threaded rods on mutipie units (Figure 4, right)Figures Bamave part end cover and thrust plates by inserting screw drivers or pry bars. (Figure 6, left) Be sure not to damage the machined suriaces. Thrust plate and roller bearings will remain with the port end cover when removed as shown on far right of Figure 5. Remove thrust plate and examine for waar, Lift off gear housing taking care not to damage the machined surfaces (Figure 6, lef). Use screw divers or pry bars as necessary. Ramove the drive and idler gear taking cara not to damage machined surfaces (Figure 6, night). Be careful to keap the gears together. You must reassemble them as pairs, since they have warkedin together.Figurs 7 ‘On mutiple section units, remove the bearing carrier (Figure 7. left). Use screw drivers or pry bars as necessary. Be careful not to damage the machined surfaces. ‘On mutipla sections units, remove the connecting shail (Figure 7, right). Lit off gear housing taking care not to damage the machned surfaces (Figure 6, leh). Use screw drivers or pry bars as necessary. Remove the drive and idler gear from shaft cover taking care not to damape machined surfaces (Figure 8, right), Be careful to keap the gears together. ‘You must reassemble them as pairs, since they have worked-in together.Remove thrust plates and inspect them for excessive wear (Figure 9, left Bearings should remain in cover. If thay do nct, or can be removed by hand, discard shaft end cover. Check thrust plata for wear and flainess. ‘you plan to replace the bearings, tun shaft end cover over and remave the shaft bearing snag ring (Figure &, right). NOTE: Wear Saiety Goggles when working with Snap Rings.Figure 10 lemove the shafi bearing from the shalt end cover with the proper toa! (Figure 10, iaft). Take care:not to damage the bearing seal. Use a bearing puller to pull the roller bearings aut of the shaft end cover (Figure 10, night). Figura 1 Flemove the ring seal (Figure 11} and inspect mating surface in the cover far deap scoring (replace shaft end cover necessary). NOTE: ‘Reuse of ring seal is not recommended.INSPECTION OF COMPONENTS CAUTIONS AND SPECIAL NOTES: Never installa part again # i does nct meet the manufacturer specticatons. Always fx the cause of the pump west The parts in hydraulic pumps and motors. work togethar'to give Baw or torque. The efficiency of a unit is variable, according to the flow loss any given group af paris permite. Be cure to teat all rebuilt pumps for acceptable performance. Make relerence to the manufacturers manual for test specifications. Gear bore Bearing Seal tore Figure #2 Figure 12 shows body assembly (blind bores) on the left and plata assembly (through bores) on the right. NOTE: All plats assembles do not hawe gear bores.Procedure to Clean Famove lip seals and weep hole plugs first. Wash flanges. plates and bodies with clean solvent made from petroleum. Use a brush to remove dit from ‘outer surfaces. Generally, a brush is not necessary to clean inner surfaces. Be especially sure that in those flange assemblies equipped with weep hole plugs, the seal drain passages are clean, Remove all sealant irom seal grooves ‘of seals will not work correctly at assembly. If sealant cannot be removed with ‘the solvent and a brush, use glass beads. [Use beads of 80 to 150 micron (size 10) with 550 to 620 kPa (80 to 90 psi) air preesure] Early flanges were ‘equipped with metallic seal drain valves. All such early flanges must be fitted with new valves, which are made of Viton material. But before instaling & new seal drain valve, a steel sleeve must be installed in the drain valve passage first. Procedure to Inspect Figure 13, left, shows fretting on the mounting face, that can be an indication that the face is bent. Use again after the face is measured and found to be acceptaiile, a comparison between two dimensions: near the pilot diameter and near the mounting bolt hole, wil jell you if the face is acceptable or not (Figure 13, right}. Use again only if the difference between the two dimensions is 0.5 mm (0.02 in) or less.Figure +4 Figure 14, left, shows ight scratches in the seal bore. NOTE: This type of damage wil not reaul in aca! cane te bore leakage if an application of 889965 Aetuining Compound iz put around the joint between the seal case and the bore when instalinga new seal ‘Figure 14, right, shows damage in the seal bore. Use again after tha bora is salvaged according to the correct procedure (see Procedure to Salvage Seal Bore. Bushing ‘The bronze used in bushings is very porous (has many very small holes}, Because of thi, the Teflon oveday gets pushed into theee holes during manidacture. Gradual wear in the loed zone [between the shaft joumal and bushing) will cause more of the bronze to show through. But the bushing can still be used agein because the surface is a mix of bronze and Teflon. ‘The bronze elso shows through when the Teflon in the non-load zone of the bushing (pressure port sida} becomes wom, and, while the surface willbe rough, the bushing can be used again.Figure 15 Figure 18, left, shows fretting in the outside diameter of the bushing in the seal area, Figure 45, right, is a typical example of bushing wear in which the bronze shows through tha Teflon. Thasa can be used again. Figure 48 Figure 16, left, chows scored and spallad bushings. Do not use again. NOTE: Bushings in Figure 16 were cut to show the condition mare clearly. Figura 16, right, is damage to the Teflon on the inside diametar of the bushing. Do net use again.Figure 17 Figure 17 indicates the Bushing has tumed in the bore. Do not use again. Inspect the bushing bore for aut-of-round after th bushing is removed. I it is out-obround by more than 0.05mm (0.002in}, do not use the casting again. ‘Abushing bore that is out-of-round is @ claar sign that the gear track is too daep: the casting in which the gears track must be replaced. Bushings are installed with the seam no mare than 1.5mm (0,06in) from a ling through the centre of the bushing bores, toward the dowel pin holes. The installation of new bushings will have an effect on the efficiency of the unit. ‘This is because new bushings will cause the gaars to move to a new position in which the tips of the gaar teeth will no longer be in contact with the wom gear track. This is one important reason to tast the efficiency of rebuilt pumps to be sure that they are acceptable according to specifications. Gear Track The maximum allowable depth in the gear track for an aluminium pump body is. 9.38mm {0.016in) on the low pressure side of the unit. ‘The maximum allowable depth in the gear track for an iran pump body is 9.3mm (.01tin) on the law pressure side of the unit.a eae Fogurs 1 Figure 18, leit, shows Burr on the edge of the gear track. Use again after the burr is removed with a knife or similar shesp instrument. Emsion, or gradual wear on the low pressure side of the gear track (Figure 1, right) wil nct have an affect on performance, unless ithas extended to the high pressure side. Extended damage will resuit in a loss in atficiency. How much loss, exactly, cannot be determined without testing. Test these castings after assembly to be sure that their level of etficienay is acceptable Pumps with this condition will run at 4 higher noise level Figura 19, Figure 1, laf, is a gear track in iron pump bedy which shows narmal wear with some discoloration. Damage caused by forsign material in the low pressure side of the gear track (Figure 19, right} will not have a negative effect on perlormance either, unless it has extanded to the high presoure side. Use again unless extended damage can cause & loss in efficiency, so test the castings after assembly.Figure 20, lef, shows sealant in the seal groove. Use again. Figure 20, right, is a damaged seal groove. Do not use again. Figuro24 Figure 21, left, shows 4 damaged seal face. Do not use again. Figure 21, right, indicates damage across the O-ring sesl area of the seal face. (Donot use again. NOTE: Similar damage across the O-ring groove can cause leakage, as can tool chatter in the bottom of the O-ting groove. Dia not use the partif it has either one of these types of damage.Threaded Hole awe Figure 22. H the bolt csnnct be tightened to the correct torque specifications, i is possible that the threaded hole ts damaged (Figure 22, leh). Piaces of aluminium in the threads of this boll are an indication that the threaded hole = damaped. Use again after aluminium is removed with a wire brush. Figure 22, right shows a damaged threaded hole. Use again after an insert is installed. Miscellaneous Figure 23. Figure 23, laf, shows side clearance that can be fet in the dowel hale. Do not use again. NOTE: Dio not reuse mating pieoe. Figure 23, right, has a crack in the casting Range.Figure 24, iat, shows & crack in the casting flange. Do not use again. Figure 24, right, is a crack in the casting flange. Do not use again. bt ’ Figure 25, lett, is a crack in the gear body. Do not use again. Figure 25, fight, shows a crack in the seal area of the port. Do not use again. Procedure to Salvage Seal Bore Most types of damage in the flange, plate, or body assembly are either acceptable as is or not at all Generally, i the partis not usable as is, salvage is ‘ot practical, except fi is seal bore damage. NOTE: ele in metorene ite cro lhes un of Ther sl) products, See Cautions and Special Notes.Salvage Procedure 1. Remove any raised metal in the bore with 180 grit crocus cloth. 2 Make sure the bore fs completely fea of of and dt and tat sy. (Use solvent to remove oi let the bare dry thoroughly) See Figure 26 left. 3. When the part is at room temperature [approximately 21°C (70°F, put a layer of Hieleasing Agent on the outside diameter of the seal cases (Figure 20, 4. Putan application on the damaged area. Be careful nat to get any into the seal drain passage. 5. Install the seal in the bore. Do not install the flange assembly for two houre. Be sure the bore is completely clean and dry. ‘Seal bore ready to install (Figure 28, nght).Gear Shaft Nomenclature Taolh pratte Kanth Vaca ‘Saline Bearing crear ‘seal “ree Figurez7 Figure 27 shows the gear shaft nomenclature. Procedure to Clean Wesh gears with a clean solvent made from petroleum. Clean carsfully so as Not to damage bearing areas. It is not necessary to remove any discolorstion {change of colour) from the gears. This is caused by oil and is ecceptable.Procedure to Inspect - Shaft Seal Area Figura 28 Figure 26 shows grooves in the ses! area which can be felt with a fingemail. Use again after the seal area is salvaged ancording to the comect procedure Corrosion in the seal area can be seen in Figure 28. Use again after corrosion is removed with 120-grit crocus cloth and motor oil. {install shaft in a lathe for the operation). Figura 28 Figure 29, Ie, shows Splines that have signs of interference. Use again after installation is adjusted to stop imterference. NOTE: Donetuse achat again ii has a twisted spline.Frettng in tha spines can be fat with a fingemail [Figura 29, right}. Donat use again f fretting exceeds 0.25 to 0.88 mm (0.010 to 0.015 in}. Figuro30 Figure 30, left, shows light spline damage. This can be used again. Figure 99, right, shows heavy spline damage. This cannot be used again.Figure 31 When reconditioning the bearing, install i in a lathe for operation. Use a flat file behind the crocus cloth to polish bearing and tooth face areas (Figure 31, lett] Bearing area shows weer caused by contaminants. Use again afar scratches are removed with 400 gril crocus cloth and mator ail Figure 31 right shows corrosion in the beefing area and tooth face. Use again after corrosion is removed with 400 gn crocus cloth and motor od_ NOTE: Ieormsion has caused pitting in the shalt, do not use the part again. Toath Face Figure 32 Figure S2 shows scratches on the gear tooth face. Use again ater most of the scratches and all the burrs are removed with £00 grit crocus cloth and motor oil. (Install in a lathe for the operation; use a flat file behind the crocus cloth to polish tooth face area )