CONSTRUCTIONEQUIPMENTREPAIRER (HYDRAULICSYSTEMS)

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EDITIONB
UnitedStates(US)ArmyEngineerSchool FortLeonardWood,Missouri65473 4CreditHours EditionDate:November1999

SUBCOURSEOVERVIEW
Thissubcourseisdesignedtoteachthebasicskillsrequiredtoadjustandrepair hydraulicpumpsandvalvesusedonengineerconstructionequipment.Informationis providedonpositivedisplacementpumpsandcontrolvalvesandtheprocedures requiredtodisassemble,adjustorrepair,andreassemblethem.Thissubcourseis presentedintwolessons,eachcorrespondingtoaterminallearningobjective. Therearenoprerequisitesforthiscourse. Thissubcoursereflectsthedoctrinewhichwascurrentatthetimeitwasprepared.In yourownwork,alwaysrefertothelatestofficialpublications. Unlessotherwisestated,themasculinegenderofsingularpronounsisusedtoreferto bothmenandwomen. TERMINALLEARNINGOBJECTIVE: ACTION: Youwilllearntoidentify,disassemble,adjustorrepair,and reassemblehydraulicpumpsandvalvesusedonengineer constructionequipment. YouwillbegiventhissubcourseandanACCPexamination responsesheet.

CONDITION:

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STANDARD:

Todemonstratecompetencyofthistask,youmustattaina minimumscoreof70percentonthesubcourseexamination.

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TABLEOFCONTENTS
Section Page

SubcourseOverview............................................................................................................i AdministrativeInstructions.............................................................................................iii GradingandCertificationInstructions............................................................................iv Lesson1:HydraulicPumps...........................................................................................11 PartA:PositiveDisplacementPumps.....................................................................12 PartB:GearPump...................................................................................................15 PartC:VanePump.................................................................................................111 PartD:PistonPump...............................................................................................112 PracticeExercise.......................................................................................................119 AnswerKeyandFeedback.......................................................................................122 Lesson2: HydraulicValves............................................................................................21 PartA:PressureControlValves...............................................................................22 PartB:DirectionalControlValves...........................................................................25 PartCControlValveRepair.....................................................................................28 PracticeExercise.......................................................................................................215 AnswerKeyandFeedback.......................................................................................218 Examination....................................................................................................................E1 AppendixA:ListofCommonAcronyms.......................................................................A1 AppendixB:RecommendedReadingList....................................................................B1 AppendixC:MetricConversionChart.........................................................................C1

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AppendixD:PublicationExtracts...............................................................................D1 StudentInquirySheets

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ADMINISTRATIVEINSTRUCTIONS
1. Numberoflessonsinthissubcourse:Two.

2. Materialsyouwillneedinadditiontothisbookletareanumbertwopencil,the ACCPexaminationresponsesheet,andthepreaddressedenvelopeyoureceivedwith thissubcourse. 3. Supervisoryrequirements:None.

4. Thefollowingpublicationsprovideadditionalinformationaboutthematerialin thissubcourse.Youdonotneedthesepublicationstocompletethissubcourse. FM5499.Hydraulics.1August1997. SoldierTrainingPublication(STP)562B1SM.Soldier'sManual,MOS62B, ConstructionEquipmentRepairerSkillLevel1.25September1990. STP562B24SMTG.Soldier'sManualandTrainer'sGuide:MOS62B, ConstructionEquipmentRepairer(SkillLevel2/3/4).15October1990. TM52350262201.UnitMaintenanceManualVol1of2forArmored CombatEarthmover(ACE),M9(NSN2350008087100)(ThisItemis Includedon EM0035).3January1997. TM52350262202.UnitMaintenanceManual,Vol2of2forArmored CombatEarthmover(ACE),M9(NSN2350008087100)(ThisItemis Includedon EM0035).3January1997. TM5241023720.UnitMaintenanceManualforTractor,FullTracked,Low Speed:DED,MediumDrawbarPull,SSNM061,TractorWithRipper,(NSN 2410012230350)TractorWithWinch,(2410012237261)TractorWith RipperandWinterizedCab,(2410012532118)TractorWithWinchand WinterizedCab,(2410012532117)(ThisItemisIncludedonEM0119). 30March1993. TM5241023734.DirectSupportandGeneralSupportMaintenanceManual forTractor,FullTracked,LowSpeed:DED,MediumDrawbarPull,SSN M061TractorWithRipper,(NSN2410012230350)TractorWithWinch, (2410012237621)TractorWithRipperandWinterizedCab, (241001253 2118)TractorWithWinchandWinterizedCab,(2410012532117)(ThisItem isIncludedonEM0119).30March1993.

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TM5380526220.OrganizationalMaintenance,Loader,ScoopType,DED, 4x4,ArticulatedFrameSteer,21/2CubicYard(J.I.CaseModelMW24C) (NSN3805011504814)(ThisItemisIncludedonEM0115). 1September1987.

TM5380526234.DirectSupportandGeneralSupportMaintenanceManual ForLoader,ScoopType,DED,4x4,ArticulatedFrameSteer,21/2Cubic Yard(J.I.CaseModelMW24C)(NSN3805011504814)(ThisItemis IncludedonEM0115).1September1987.

GRADINGANDCERTIFICATIONINSTRUCTIONS
Examination:Thissubcoursecontainsamultiplechoiceexaminationcoveringthe materialinthetwolessons.Afterstudyingthelessonsandworkingthroughthe practiceexercises,completetheexamination.Markyouranswersinthesubcourse booklet,thentransferthemtotheACCPexaminationresponsesheet.Completely blackouttheletteredovalthatcorrespondstoyourselection(A,B,C,orD).Usea numbertwopenciltomarkyourresponses.WhenyoucompletetheACCPexamination responsesheet,mailitinthepreaddressedenvelopeyoureceivedwiththissubcourse. Youwillreceiveanexaminationscoreinthemail.Youwillreceivefourcredithoursfor successfulcompletionofthisexamination.

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THISPAGEISINTENTIONALLYLEFTBLANK.

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LESSON1 HYDRAULICPUMPS
CriticalTasks:0512351180 0512352186

OVERVIEW
LESSONDESCRIPTION: Thislessonwillintroduceyoutopositivedisplacementpumpsusedonengineer constructionequipment.Includedarethestepsrequiredtodisassemblepumps,repair orreplacecomponents,andreassemblepumps. TERMINALLEARNINGOBJECTIVE: ACTION: Youwilllearnthetypesofpositivedisplacementpumpscommonly usedonengineerconstructionequipmentandtheprocedures requiredtodisassemble,repair,andreassemblethem. Youwillbegiventhematerialcontainedinthislesson.Youwill workatyourownpaceandinyourownselectedenvironmentwith nosupervision. Youwillcorrectlyanswerthepracticeexercisequestionsatthe endofthelesson. ThematerialcontainedinthislessonwasderivedfromSTP 562B1SM,STP562B24SMTG,TM52350262201,TM 52350262202,TM5241023734,TM5380526220,and TM5380526234.

CONDITION:

STANDARD:

REFERENCES:

INTRODUCTION
Hydraulicsisthescienceofusingforceandmotiontomoveconfinedliquid.Ina hydraulicdevice,atransferofenergytakesplacewhenliquidissubjecttopressure. Thefollowingfourbasicprinciplesgovernhydraulics:

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Liquidshavenoshapeoftheirown;theyconformtotheshapeoftheir container. Liquidsareincompressible. Liquidstransmitappliedpressureinalldirections. Liquidsprovideincreasedforce.

Thefollowingkeyfactswillhelpyougainanunderstandingofhydraulics: Hydraulicpowerisgeneratedfrommechanicalpower. Hydraulicenergyisachievedbyconvertinghydraulicpowertomechanical energy. Hydraulicenergyconsistsofpotential(pressureenergy),kinetic(energyof movingliquids),andheat(energyofresistancetofluidflow[friction]). Hydraulicenergyisneithercreatednordestroyed,onlyconvertedto anotherform. Energyinahydraulicsystemisconsideredeitherwork(gain)orheat(loss). Heatiscreatedandenergyislostwhenamovingliquidisrestricted.

PARTA:POSITIVEDISPLACEMENTPUMPS
11. General.Pumpsareusedtoliftortransportliquid.Theymayraisetheliquid levelorforcetheliquidthroughahydraulicsystem. a. Pumpsinahydraulicsystemareusedtoconvertmechanicalenergyto hydraulicenergy.Mechanicalpowercreatesapartialvacuumatthepump'sinletport sothatatmosphericpressureinthereservoircanforceliquidthroughtheinletlineand intothepump.Mechanicalpowerthendeliversthisliquidtotheoutletport,forcing theliquidintothehydraulicsystem. b. Positivedisplacementpumpsarethemostcommonhydraulicpumpson engineerconstructionequipment.Thesepumpshavearotarymotionthatcarries liquidfromtheinletporttotheoutletport.Theyproduceapulsatingflowofliquid. Becausethesepumpshaveapositiveinternalsealtopreventleakage,theiroutputis relativelyunaffectedbysystemvariations.Forexample,ifanoutletportisblocked, pressureinthepumpwillincreaseuntiltheequipmentstallsorthepump'smotorfails. Positivedisplacementpumpsareclassifiedaccordingtotheelementthattransmitsthe liquidgear,vane,orpiston.

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12. GearPump.Thegearpump(Figure11)consistsofadrivinggearandadriven gearenclosedinafittedhousing.Thegearsrotateinoppositedirections,andthegear teethmeshinthehousingbetweentheinletandoutletports.Astheteethofthetwo gearsseparate,apartialvacuumisformed,whichdrawsliquidthroughtheinletport intochamberA.LiquidinchamberAisthentrappedbetweentheteethofthetwo gearsandthehousingandiscarriedthroughtwopathstochamberB.Astheteeth meshagain,liquidisforcedthroughtheoutletport.

Chamber A To inlet port Driven gear

Housing

Driving gear Chamber B Outlet port

Figure11.Gearpump 13. VanePump.Inavanepump,aslottedrotorsplinedtothedriveshaftrotates betweenfittedsideplatesinsideanellipticalorcircleshapedring(Figure12,page 14).Polished,hardenedvanesslideinandoutoftherotorslotsandfollowthering's contourbycentrifugalforce.Chambersformedbetweensucceedingvanescarryoil fromtheinletporttotheoutletport.Apartialvacuumiscreatedattheinletasthe spacebetweenthevanesincreases,forcingoilthroughtheoutletastheareainthe pumpingchamberdecreases.Becausethenormalwearpointsonavanepumparethe tipsandtheringsurface,thesepartsarespeciallyhardenedandground.

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Drive shaft

Slotted rotor Elliptical ring

Inlet port

Outlet port

Vanes

Figure12.Vanepump a.Thevanepumpistheonlypumpdesignedwithautomaticwearcompensation. Aswearoccurs,thevanesslideoutoftherotorslotsandcontinuetofollowthering's contour.Thus,efficiencyremainshighthroughoutthelifeofthepump. b.Vanepumpscanbeassembledtorotateeitherleftorright.Corresponding arrowsstampedonthepump'sbodyandcartridgeindicaterotationdirection.Rotation isalsoindicatedinthemodelnumber.Pumpsassembledforlefthandrotation (counterclockwisewhenviewedfromthedriveshaftend)havetheletters"LH"addedto themodelnumber.Pumpsassembledforrighthandrotationhavenomarkings. 14. PistonPump.Onaninlinepistonpump,thedriveshaftandthecylinderblock areonthesamecenterline(Figure13).Reciprocationofthepistonsoccurswhenthe pistonsrunagainstaswashplateasthecylinderblockrotates.Thedriveshaftturns thecylinderblock,whichcarriesthepistonsaroundtheshaft.Thepistonshoesslide againsttheswashplateandareheldagainstitbytheshoeretainerplate.Theangleof theswashplatecausesthecylinderstoreciprocateintheirbores.Whenapistonbegins toretract,theopeningontheendoftheboreslidesovertheinletslotinthevalveplate andoilisdrawnintotheborethroughlessthanonehalfarevolutionofthecylinder block.Asolidareaiscreatedinthevalveplate,andthepistonretracts.Asthepiston beginstoextendtheopening,thecylinderbarrelmovesovertheinletportandoilis forcedthroughtheoutletport. a. Themajorcomponentsofapistonpumpconsistofahousing,a bearingsupporteddriveshaft,arotatinggroup,ashaftseal,andavalveplate.The valveplatecontainstheinletandoutletportsandfunctionsasthebackcover.The rotatinggroupincludesacylinderblock,whichissplinedtothedriveshaft;asplined sphericalwasher;acylinderblockspring;ninepistonswithshoes;aswashplate;anda shoeretainerplate.Whenthisgroupisassembled,thecylinderblockspringforcesthe cylinderblockagainstthevalveplateandthesphericalwasheragainsttheshoe

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retainerplate.Theninepistonshoesareheldpositivelyagainsttheswashplate, ensuringthatthepistonsreciprocateasthecylinderturns.Infixeddisplacement pumps,theswashplateisstationary.

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Housing Cylinder-block spring

Shoe-retainer plate Swash plate

To inlet port To outlet port

Drive shaft

Valve plate Cylinder block

Figure13.Pistonpump
Piston Piston shoe

Spherical washer

Figure13.Pistonpump b. Displacement(outflow)fromthepistonpumpdependsonthenumberofpistons, theirbore,andtheirstroke.Theswashplate'sangledeterminesthestroke;therefore, thestrokecanbechangedbyalteringtheangle(Figure14).

0
Maximum displacement Partial displacement Zero displacement

Figure14.Pistonpumpdisplacement

PARTB:GEARPUMP
15. General.TheJ.I.CaseModelMW24Cscooploaderhasatwosection pumponesectionprovideshydraulicpowerforthesteeringsystem;theothersection

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providespowerfortheloadersystem.Thismodelhasageartype,fixeddisplacement pumplocatedontherearof,anditisdrivenbythetransmission.Hydrauliclinescarry fluidfromthereservoirtothepumpandfromthepumptothecontrol,demand,and reliefvalves. 16.RemovalandRepairoftheGearPump.Whenthegearpumpbreaksdownor doesnotoperateproperly,themaintenancesupervisorinstructstheconstruction equipmentrepairerintheproceduresnecessarytodeterminetheextentofdamageand possiblerepairs.Thefirststepinthisprocessistodrainthereservoir.Thepumpis thenremovedfromthetransmissionandcompletelydisassembledbeforecleaningor repairsbegin.Theremovalanddisassemblyprocessrequiresseveralsteps;eachstep mustbeperformedintheorderlisted. a. RefertoFigure15andusethefollowingstepstodrainthereservoironthegear pump: Removethefillerplug(1)onthehydraulicreservoirslowlytorelieveair pressure. Removethedrainplug(2),anddrainthefluidfromthereservoirintoa container. Turnthefrontendloaderfullytotheleftorright,andengagethelocking bar.

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Figure15.HydraulicreservoirofaJ.I.CaseModelMW24Cscooploader

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b.RefertoFigure16andusethefollowingstepstoremovethegearpump: Removethehoseassembliesfromthegearpump,anddrainthehydraulic fluidintoacontainer. Supportthehydraulicpump(3),andremovethetwocapscrews(1)and lockwasher(2). Removethepump(3)andbracket(4)fromthetransmissioncarefully. Placeaprotectivecoveroverthesplineddriveshaftonthepumpandthe mountingpadtopreventforeignmaterialfromenteringthetransmission.

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Figure16.Hydraulicgearpump c. RefertoFigure17,page18,andusethefollowingstepstodisassemblethe gearpump: Scribealinelengthwisealongthepumptoaidinalignmentduring reassembly. Removetherollerbearings(6,18,and30)withabearingpuller.Replace themasnecessary. Removetheseals(7,10,11,19,25,and31)anddiscard. Removetheseal(32)fromtheshaftendcover(34). Discardthepreformedpackingandtheseal(32).

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15
2 27 3 8 5 6 4 13 3 14 5 15 11 19 30 17 30 16 18 17 25 30 20 29 25 0 12 21 32 1 17 30 22 30 23 0 16 30 18 33 9 7 10 1

5 19 17

17

17

29 0

31 1

30

24 30

30

29 30

26 28 30 30

32 0

34

1. 2. 3. 4. 5. 6. 7. 8.

Nuts (4) 10. Seal 19. Seals (2) 28. Thrust plate Washers (4) 11. Seal 20. Dowel pin 29. Pocket seals (6) Port end cover 12. Dowel pin 21. Connecting shaft 30. Roller bearings (2) Thrust plate 13. Driving gear 22. Driving gear 31. Seal Pocket seals (6) 14. Driven gear 23. Driven gear 32. Seal Roller bearings (2) 15. Bearing carrier 24. Gear housing 33. Plug Seal 16. Thrust plates (2) 25. Seals (2) 34. Shaft end cover Dowel pin 17. Pocket seals (12) 26. Dowel pin

Figure17.Gearpump,explodedview d. Cleanallmetalpartsusingcleaningsolvent(specificationPD680)andallow partstoairdry.Donotuseclothstodryparts. 17. InspectionoftheGearPump.RefertoFigure17,andcompletethefollowing stepstoinspectthegearpump:

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a.Inspectthegearsurfacesandtheedgesofthegearteethforburrs,scoring,or wear.Removeburrswithafinestone.Replacethegearsiftheyarewornorbadly scored. NOTE: Gearsmustbereplacedinsets. b. Inspectthedrivinggear(22),andreplaceitifitisroughordamagednearthe sealorifwearatthebearingsurfaceshascausedtheshaftdiametertodifferfromthe designateddiameterbymorethan0.001inch. c. Inspecttherollerbearings(6,18,and30)forfreerollers,pitting,orwear. Replacethebearingsasneeded. d. Inspectthegearhousings(9and24)forwearanddamage,andreplacethemas needed.Inspectthematingsurfacesofthegearhousings(9and24),bearingcarrier (15),portendcover(3),andshaftendcover(34)forburrsanddamage.Removeburrs withafinefileorstone.Replacetheentirepartifthesurfaceisbadlydamaged. e. Inspectthethrustplates(4,16,and28)forwearandscoring.Replacethe platesasneeded. 18. ReassemblyoftheGearPump.RefertoFigure17,andcompletethe followingstepstoreassemblethegearpump: a. Coatthepreformedpacking,thepocketseals(5,17,and29),andtheseals(7, 10,11,19,25,31,and32)withanoilsolublegreasebeforeinstallingthem. b. Presstheseal(32)intotheshaftendcover(34)withthelipfacingtheinsideof thebore. c. Usesoftjawstoplacetheshaftendcover(34)inavise.Installthepreformed packingandrollerbearings(30)intheshaftendcover(34). d. Greasethesixpocketseals(17)andinstalltheminthetwomiddleslotsofthe thrustplates(16).Installthethrustplate(4)onthedriveshaftwiththepocketseal facingtheshaftendcover(34).Tapthethrustplate(4)inplace.Leaveaclearanceof 0.03125inchbetweenthethrustplate(4)andtheshaftendcover(34). e.Installthesixouterpocketseals(5)inthethrustplate(4).Pushthepocket seals(5)intotheslotsuntiltheendsmakecontactwiththerollerbearings(18).Tap thethrustplate(4)solidlyintopositionontheportendcover(3).Usearazorbladeor asharpknifetotrimtheexposedendsonthepocketseals(5)sothattheyareflush withthesidesofthethrustplate(4).

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f. Usesoftjawstoplacethegearhousing(24)inavise.Installthethrustplate (16)asdescribedinparagraph18d. g. Placetheportendcover(3)inavise.Installtheseal(7),therollerbearings (6),andthethrustplate(4). h. Placethebearingcarrier(15)inavise.Installtheseals(19),theroller bearings(18),andthethrustplates(16). i. Placetheassembledshaftendcover(34)inavise.Coatthethrustplate(28) withengineoil.Installthedrivinggear(22)andthedrivengear(23)intheshaftend cover(34). j. Installtheseals(25)inthegroovesonthegearhousing(24).Installthe housingoverthegearsontheshaftendcover(34).Tapthegearhousing(24)witha leatherhammertoseatitonthecover.Lubricatethegearswithengineoiltoprovide initiallubrication. k. Installtheconnectingshaft(21)intheboreofthepumpshaftanddrivinggear (22).Installthebearingcarrier(15)onthegearhousing(24),andalignthescribe marks.Tapthebearingcarrier(15)inplace. l. Installthedrivinggear(13)ontheconnectingshaft(21)andinstallthedriven gear(14)intheboreofthebearingcarrier(15).Insertseals(10and11)inthegrooves onthegearhousing(9).Placethegearhousing(9)overthegearsandtapthehousing inplace.Lubricategearswithengineoil. m.Placetheportendcover(3)onthegearhousing(9)andtapinplace.Thread fourstudsthroughtheportendcover(3)andintotheshaftendcover(34)untilthe stud'sendsextendabovetheportendcover(3).Insertthefourwashers(2)andnuts (1).Tightenthenuts(1)toasnugfit. n.Rotatetheconnectingshaft(21)andthedrivinggear(22)witha6inch wrench.Checktheeaseofoperation.Iftheconnectingshaft(21)rotatesfreely,tighten thenuts(1)toatorqueof200footpounds.Rotatetheconnectingshaft(21),andcheck theeaseofoperationasecondtime.Thepumpshouldrotatefreelywithnoevidenceof binding. o.Coatthesplinesoftheconnectingshaft(21)andthedrivinggear(22)with grease. 19.InstallationoftheGearPump.Completethefollowingstepstoinstallthe assembledgearpump:

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a. RefertoFigure17,page18.Removetheprotectivecoverfromthesplined connectingshaft(21)ofthegearpump,andcoattheshaftwithgrease.Installthe pumponthemountingpad. b. RefertoFigure16,page17.Installthegearpumpandsecureitwithtwo screws(1)andlockwashers(2).Connectthehydrauliclinestothepump. c. RefertoFigure15,page16,andcontinuewiththefollowingstepstoinstall theassembledgearpump: Replacethedrainplug(2)andstrainerassembly(6)inthereservoir. Replacethecover(4)andthegasket(5)onthereservoir,andsecurethe coverwithscrews(3). Refillthereservoirwithhydraulicfluid,andreplacethefillerplug(1). Starttheengine,andcheckthepumpandlinesforleaks.Operatethe hydrauliccontrolsandcheckpumpoperation.

PARTC:VANEPUMP
110. General.Adoublesection,insert,hydraulicvanepumpisusedonCaterpillar D7Gtractors.Thepumpisboltedontheengine'srearpowertakeoffhousingandis drivenbytherearpowertakeoffidlergear. a.Avanepumpconsistsofasmallandalargesection,bothofwhichsharea commoninlet.Thelargesectionprovideshydraulicpowerforthebladeliftandscraper circuits.Thebladeliftcircuitiscontrolledbyavalvelocatedinthehydraulictank. Thescrapercircuitiscontrolledbyavalvelocatedintheequipmentoperator's compartment.Thesmallsectionpowersthebladetiltcircuitandiscontrolledbya valvemountedinthehydraulictank. b.Thevanepumprequiresacontinuousflowofcleanoiltolubricatetheclosely fittedparts.Ifinletoilisnotavailable,thepumpmayseizeorsustaindamagewhen theengineisstarted.Insufficientoilsupplymayresultfromcloggedorleakinginlet linesoralowoillevel.Thepumpmayneedtoberemovedforcleaningorrepair. 111.RemovaloftheVanePump.Toremovethevanepumpfromitsmounting, completethefollowingsteps: a.Closetheshutoffvalvelocatedonornearthereservoir. b.Disconnectthesuction(intake)andpressure(outlet)hoses.

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c.Removethevanepumpfromitsmountingbracketorhousing. 112.DisassemblingtheVanePump.RefertoAppendixD,pagesD7throughD 10,todisassemblethevanepump. 113. Cleaning,InspectingandRepairingtheVanePump.Afterthevanepump isdisassembled,thoroughlycleananddryallparts(refertoAppendixD,pagesD3 throughD6andD10).Carefullyinspectandrepaircleanedpartsaccordingtothe followingprocedures: a.DiscardtheintakeandexhaustplatesealsandOrings.Washallmetalparts inmineraloilsolvent,anddrythemwithfiltered,compressedair.Placethepartsona cleansurfaceforinspection. b.Inspectthesurfacesofthepumphousing,rotorring,androtorforscoringand wear.Removelightscoringmarksbylappingwithanextrafineemeryclothorlapping compound.Replaceallheavilyscoredorbadlywornparts. c.Checktheintakeandexhaustendplatesforscoringandwear.Replacebadly wornorheavilyscoredendplates. d. Inspectthevanesforburrs,wear,orplayintherotorslots.Iftoomuchplayis noted,replacetherotorandvanes.Refertotherepairandreplacementstandards listedintheappropriateTMtodetermineifreplacementisnecessary. e.Checktheslipringandslipringwasherforscoringandwear.Replaceheavily scoredorbadlywornparts. f. Checkthebearingsforwearandfit.Tocheckforpittedorcrackedballsor race,applypressureandslowlyrotatethebearing.Replacethebearingifitiswornor scored.Placethedriveshaftintothepilotbearingandcheckforexcessiveplay. Replacethepilotbearingifnecessary.Refertotherepairandreplacementstandards listedintheappropriateTMtodeterminewhenreplacementisnecessary. g.Inspecttheoilsealmatingsurfaceofthedriveshaftforscoringandwear.If marksonthedriveshaftcannotberemovedwithlightpolishing,replacethedrive shaft. h.CoatOringswithasmallamountofpetroleumjellytoholdtheminplace duringreassembly. 114.LubricatingandAssemblingtheVanePump.Lubricateallpartswithclean oil.RefertoAppendixD,pagesD10throughD14toassemblethevanepump.

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115. TestingtheVanePump.RefertoAppendixD,pagesD14throughD18,totest thevanepump.

PARTD:PISTONPUMP
116. General.ThepistonpumpisusedontheACE.Thecompensatinghydraulic pumpisatenpiston,variabledisplacement,constantpressure,radialpump. WARNING TheACE'shydraulicsystemisunderhighpressure.Relievepressurebefore disconnectinganyhydrauliccomponents.Afterpressureisrelieved,waitat least4minutesbeforedisconnectinganyhoseorfitting.Failuretocomply mayresultinsevereinjury.

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117 RemovingthePistonPump.Completethefollowingstepstoremovethe pistonpumpfromitsmounting: a. RefertoFigure112anddisconnectthepistonpumpusingthefollowingsteps: Disconnectthehoses(1,2,and3)fromelbows(4,5,and6). Loosenthescrew(8)ontheclamp(9),andremovetheclampfromthe pump(7).

a. Disconnecthoses(1,2,and3)fromelbows(4,5,and6)atpump(7).
7 4 b. Loosenscrew(8)ofclamp(9),andremoveclamp(9)frompump(9).

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Figure112.Disconnectingthepistonpump b. RefertoFigure113,page114,toremovethepistonpump.Removethetwo selflockingscrews(10),washers(11),pump(7),andgasket(12)fromthetransfercase (13).Discardthescrews(10)andthegasket(12).

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11 10

12

Figure113.Removingthepistonpump 118. Disassemblingthepistonpump.Completethefollowingstepstodisassemble thepistonpump: a. RefertoFigure114,anddisassemblethepistonpumpusingthefollowing steps:

Figure114.Pumpdisassembly,PartI
4 14

19 18

16

17

5 6

15

Figure114.Disassemblingthepistonpump,partI

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Removetheelbows(4and6)andtheseals(14and15)fromthepump (7).Discardthepacking.

Removetheelbow(5),thereducer(16),theseal(17),theelbow(18),and theseal(19)fromthepump(7).Discardtheseals(17and19).

b. RefertoFigure115,anddisassemblethepistonpumpusingthefollowing steps: Removethefourcapscrews(1),compensator(2),gasket(3),andseal(4) fromthecover(5).Discardthegasket(3)andtheseal(4).

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Figure115.Disassemblingthepistonpump,partII Removethefourscrews(6),cover(5),andgasket(7)fromthehousing(8). Discardthegasket.

WARNING Removetherotatinggroupasanassembly.Failuretocomplymayresultin damagetoequipment. c. RefertoFigure116,page116,anddisassemblethepistonpumpusingthe followingsteps:

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Tipthehousing(8)forwardandremovetherotatinggroup(9)fromthe shaft(10).

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14 13 11 16 17

15

12

10 8

Figure116.Disassemblingthepistonpump,partIII Removetheswashplate(11)andthetwoscrews(13)fromtheyoke(12). Applypressuretotheyoke(12)anduseawooddoweltodriveoutthetwo pintles(14). Removetheyoke(12),seat(15),andtwosprings(16)fromtheshaft(10) andhousing(8). Removethepacking(17)fromthepintles(14).Discardtheseal(17).

119. ReassemblingthePistonPump.Completethefollowingstepstoreassemble thepistonpump: NOTE:Lightlycoatallpartswithlubricatingoilbeforeassembly.Apply lubricatingoiltopackingbeforeinstallation. a. RefertoFigure116,andreassemblethepistonpumpusingthefollowing steps: Installtheseal(17)onthepintles(14). Installthetwosprings(16),seat(15),andyoke(12)onthehousing(8). Pressdownontheyoke(12)andalignthescrewholeswiththeholesinthe pintle(14)seat.Installtwopintlesonthehousing(8)andtheyoke(12).

NOTE:Thepintlegroovesmustaligninthecenteroftheyoke'sscrewholes.

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EN 5260

Installthetwoscrews(13)ontheyoke(12).Tightenthescrews(13)to75 to80footpounds. Installtheswashplate(11)ontheyoke(12),chamferedsidefirst.Coatthe faceoftheswashplate(11)withlubricatingoil. Laythehousing(8)onitssideandcarefullyslidetherotatinggroup(9)on theshaft(10),aligningthesplines.Coatthefaceoftherotatinggroup(9) withlubricatingoil.

NOTE:Thecoverwillnotfitflushuntilthescrewsaretightened. b. RefertoFigure115,page115,andreassemblethepistonpumpusingthe followingsteps: Installthegasket(7)andcover(5)onthehousingwiththefourscrews(6). Tightenthescrews(6)to25to35footpounds. Installthepacking(4),gasket(3),andcompensator(2)onthecover(5)with fourscrews(1).Tightenthescrews(1)to60to70footpounds.

120.InstallingthePistonPump.Completethefollowingstepstoinstallthepiston pump: NOTE:Newpumpsaredeliveredwitha0.25by0.25inchkeyinstalledonthe shaft.Discardthiskeyandusea0.25by0.225inchkey. a. RefertoFigure112,page113.Installtheclamp(8)onthepump(7). b. RefertoFigure113,page114,andinstallthepistonpumpusingthe followingsteps: Cleanthemountingsurfacesofthepump(7)andtransfercase(13). NOTE:Applylubricatingoiltothescrewthreadsandpackingbefore installation. Installthegasket(12)andthepump(7)onthetransfercase(13)withthe washer(11)andselflockingscrews(10).

c. RefertoFigure114,page114.Installthepacking(14),elbow(4),packing (15),elbow(6),packing(17),reducer(16),packing(19),elbow(18),andelbow(5)on

EN 5260

1-22

pump(7).Thepositionoftheelbow(6)shouldpointslightlydownwardtopreventthe hosefrominterferingwiththeejector.

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EN 5260

d. RefertoFigure112,page113,andinstallthepistonpumpusingthe followingsteps: WARNING Ensurethatthepumpisprimedwithlubricatingoil.Failuretocomplymay resultindamagetoequipment. ConnectSPNSNPUMP7hose(3)totheelbow(6). Turntheelbow(4)toanuprightposition.Fillthepump(7)with lubricatingoilthroughtheuprightelbow(4)untiloiloverflowsfromthe elbow(5). Turntheelbow(5)toadownwardposition. ConnectSPNSNPUMP9hose(2)totheelbow(5)andconnectSPNSN DRAIN7Vhose(1)totheelbow(4).

EN 5260

1-24

LESSON1 PRACTICEEXERCISE
Thefollowingitemswilltestyourgraspofthematerialcoveredinthislesson.Thereis onlyonecorrectanswerforeachitem.Whenyouhavecompletedtheexercise,check youranswerwiththeanswerkeythatfollows.Ifyouansweranyitemincorrectly, studyagainthatpartwhichcontainstheportioninvolved. 1. Hydraulicenergyisachievedbyconvertinghydraulicpowerto_____________ energy. A. B. C. D. Electrical Mechanical Solar Kinetic

2. Positivedisplacementpumpsareclassifiedaccordingtotheelementthattransmits theliquid.Whatarethethreeclassifications? A. B. C. D. Plunger,vane,androtary Centrifugal,rotary,andsuction Gear,vane,androtary Gear,vane,andpiston

3. Followingdisassemblyofagearpump,youshould___________________oldseals andpreformedpacking? A. B. C. D. Reuse Discard Turnin Store

4. Scribealinelengthwisealongthegearpumptoaidinalignmentduring __________. A. B. C. D. 5. Replacement Removal Reassembly Disassembly

Followinggearpumpdisassembly,use_________________tocleanallmetalparts.

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EN 5260

A. B. C. D.

Kerosene Solvent Gasoline Dieselfuel

6. Allpreformedpacking,pocketseals,andsealsonagearpumpshouldbecoated with__________________beforeinstallation. A. B. C. D. 7. Motoroil Hydraulicfluid Oilsolublegrease Gearoil

Whatshouldbeusedtoremoveburrsfromthebearingcarrierofagearpump? A. B. C. D. Grinder Roughfile Finefile Steelwool

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1-26

THISPAGEISINTENTIONALLYLEFTBLANK.

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LESSON1 PRACTICEEXERCISE ANSWERKEYANDFEEDBACK

Item 1.

CorrectAnswerandFeedback B.Mechanical Hydraulicenergyisachievedbyconverting...(page12,Introduction) D.Gear,vane,andpiston Positivedisplacementpumpsareclassified...(page12,para11b) B.Discard Removetheseals...(page17,para16c)

4. 5.

C.Reassembly Scribealinelengthwisealongthepump...(page17,para16c) B.Solvent Cleanallmetalpartsusing...(page18,para16d) C.Oilsolublegrease Coatallpreformedpacking...(page19,para18a) C.Finefile Removeburrswitha...(page19,para17d)

6.

7.

EN 5260

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LESSON2 HYDRAULICVALVES
CriticalTask:0512352188

OVERVIEW
LESSONDESCRIPTION: Inthislesson,youwilllearnthestepsrequiredtotest,adjust,andrepairhydraulic valvesonengineerconstructionequipment. TERMINALLEARNINGOBJECTIVE: ACTION: Youwilllearntorepairhydraulicvalvesonengineerconstruction equipment. Youwillbegiventhematerialcontainedinthislesson.Youwill workatyourownpaceandinyourownselectedenvironmentwith nosupervision. Youwillcorrectlyanswerpracticeexercisequestionsattheendof thelesson. ThematerialcontainedinthislessonwasderivedfromFM5499 STP562B24SMTG,TM5380526220,andTM5380526234.

CONDITION:

STANDARD:

REFERENCES:

INTRODUCTION
Hydraulicsystemsusevalvestomovehydraulicfluidoroilfromonepointtoanother. Toensuretheefficientoperationofequipment,theconstructionequipmentrepairer mustbeknowledgeableincontrolandrepairprocedures.Inahydraulicsystem,valves controltheactuators.Anactuatorisacylinderthatconvertshydraulicenergyto mechanicalenergy.Forexample,thetiltcylinderonaCaterpillarD7orD8dozerisan actuatorthatcontrolsthebladedirection.

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EN 5260

a.Valvesareoftenreferredtoasthe"control"ofthehydraulicsystem, particularlywhenseveralarebuiltintoasingleassembly.Valvesassertcontrolinthe hydraulicsystemto Regulatepressureandcreatespecialpressureconditions. Regulatetheflowrateanddirectionoffluidtopartsofthehydraulic system.

b.Valvesareratedbytheirsize,pressurecapabilities,andpressuredropversus flowcapabilities.Mostarenamedfortheirfunction,butsomearenamedfortheir construction.Forexample,apressurereliefvalveisnamedforitsfunction,anda poppetvalveisnamedforitsconstruction. c. Valveconstructionrangesfromasimpleballandseatarrangementtoa multielement,spooltypevalvewithjetpipepilotstageandelectricalcontrol.General constructionclassificationbeginswithsimplevalvesandbuildstocomplexdesigns.

PARTA:PRESSURECONTROLVALVES
21. General. a. Pressurecontrolvalvesarethemostcommonvalvesonengineerconstruction equipmentwithhydraulicsystems.Theyareusedto Regulatepressure. Createspecificpressureconditions. Controltheorderinwhichactuatorsoperate.

b. Pressurecontrolvalvesoperateinhydraulicbalance.Hydraulicbalanceoccurs whenpressureononesideorendofaball,poppet,orspoolisopposedbyaspringon theoppositeend.Duringoperation,thepositionofthevalvecausesthehydraulic pressuretobalancewiththeforceofthespring.Becausespringforcedifferswith compressiondistance,theamountofpressurecandiffer.Thepressurecontrolvalve hasinfinitepositioning.Itcancontrolconditionsfromalargetoasmallvolumeoffluid flow,oritcancompletelyrestrictfluidmovement.

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2-2

22.Classification. a. Pressurecontrolvalvesareclassifiedasnormallyclosedornormallyopen.The mostcommontype,thenormallyclosed,blockstheflowoffluidfromtheinletportto theoutletportuntilpressurebuildshighenoughtocauseunbalancedoperation.Flow inanormallyopenvalvemovesfreelyuntilthevalveoperatesinbalance.Theflowis thenpartlyrestrictedorcompletelycutoff. b. Pressureoverrideoccurswhenanormallyclosedvalveoperatesinbalance. Becausepressureincreasesastheheightofthecompressionspringisreduced,the pressurewhenthevalvecracksorbeginstopassflowthroughtheoutletportisless thanwhenitpassesalargevolume(fullflow).Thedifferencebetweenfullflow pressureandcrackingpressureiscalledoverride. 23.PressureReliefValve. a. Thereliefvalveisthemostcommonpressurecontrolvalve.Reliefvalveshave twofunctions.Theyprovideoverloadprotectionforcircuitcomponents,andtheylimit theforce(torque)exertedbyalinearactuatororrotarymotor.Thefunctionofthe reliefvalvemaychange,dependingonthesystem'sneeds.Thesevalvesareclassified assimpleorcompound,dependingontheirdesign. b. Theinternaldesignofallpressurereliefvalvesissimilar.Thevalveshavetwo sectionsabodyandacover.Thebodycontainsapiston,whichisretainedonitsseat byoneormoresprings.Thecover,alsocalledthepilotvalvesection,containsthe adjustingscrew.Theadjustingscrewcontrolsfluidmovementtothepump'sbodyand controlsthepressure(expressedinpoundspersquareinch[psi])withinrangeofthe valve'sratedcapacity. 24. SimplePressureReliefValve. a. Asimplepressurereliefvalvehasonlyonespring.Thevalveisinstalledso thatoneportconnectstothepressureline(inlet)andtheotherconnectstothe reservoir(outlet).Theballonthesimplepressurereliefvalveisheldonitsseatbythe thrustofthespring.Theamountofthrustexertedcanbemodifiedbyturningthe adjustingscrew.Whenpressureattheinletisinsufficienttoovercomethespringforce, theballremainsonitsseatandthevalveisclosedasshowninFigure21,page24. Thepositionoftheballpreventstheflowoffluidthroughthevalve.Whenthepressure attheinletexceedstheadjustedspring'sforce,theballmovesoffitsseatandthevalve opens,allowinghydraulicfluidoroilfromthepressurelinetoflowthroughthevalveto thereservoir.Thisflowpreventsapressureincreaseinthepressureline.When pressuredecreasesbelowtheadjustedspring'sforce,theballisreseatedandthevalve closes.

2-3

EN 5260

Adjusting screw

Spring

To reservoir Seat Ball

From pressure line

Figure21.Simplepressurereliefvalve b. Thespringforceinasimplepressurereliefvalvecausesgreaterfullflow pressurethancrackingpressure.Whenoperatingatfullflowcapacity,thehigh pressurecausesthevalvetooperateinanoverridemode.Insomecases,theoverride pressureisalmostashighorhigherthanthevalve'sratedcapacity. 25.CompoundPressureReliefValve. a. Acompoundpressurereliefvalvehasapoppetandaspringtoadjustfluidflow (Figure22).TheclosedviewinFigure22showsthatpassage1isusedtomaintain thehydraulicbalanceinthepistonwhenthevalve'sinletpressureislessthanthe pressuresetting.Thevalvesettingisdeterminedbythethrustoftheadjustingspring againstthepoppet.Whenthepressureatthevalveinletreachesthevalvesetting,the pressureinpassage2risestoovercomethethrustofspring1.Whentheflowthrough passagelcreatessufficientpressuredroptoovercomethethrustofspring2,thepiston risesoffitsseatasshownintheopenview.Thisallowshydraulicfluidoroiltopass throughthedrainageporttothereservoirandpreventsanyfurtherincreasein pressure.

EN 5260

2-4

Drainage port Poppet Spring 1

Adjusting screw

Passage 2

Spring 2

Piston Inlet

Passage 1

Outlet

Closed view

Open view

Figure22.Compoundpressurereliefvalve b.Pressurereliefvalvesthatprovideemergencyoverloadprotectionmustbe periodicallycleanedeveniftheyarenotoperatedoften.Tocleanthevalve,reducethe pressureadjustmentandoperatethevalveunderreducedpressureforafewminutesto cleanouttheaccumulatedsludgedeposits.Adjustthepressuretotheprescribed setting.

PARTB:DIRECTIONALCONTROLVALVES
26. ComplexDirectionalControlValves.Complexdirectionalcontrolvalvesare usedonengineerconstructionequipment,includingtheJ.I.CaseScoopLoaderModel MW24C.Allcomplexdirectionalcontrolvalvescontrolthedirectionoffluidflow,but theyvaryconsiderablyinphysicalcharacteristicsandoperation.Thevalvingelement intheseunitsisclassifiedunderoneofthefollowingtypes: Poppetthepistonorballmovesonandoffaseat. Rotarythespoolrotatesarounditsaxis. Slidingspoolthespoolslidesaxiallywithinabore.

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EN 5260

27.ValveClassification. a. Directionalcontrolvalvesmaybeclassifiedaccordingtothemethodusedto actuatethevalvingelement.Apoppetvalveisusuallyhydraulicallyoperated.A rotaryspoolvalvemaybeoperatedmanually(leverorpistonaction),mechanically(cam ortripaction),orelectrically(solenoidaction).Theslidingspoolvalvemaybeoperated manually,mechanically,electrically,hydraulically,orincombination. b.Directionalcontrolvalvesmayalsobeclassifiedaccordingtothenumberof positionsinthevalvingelementorbythetotalnumberofflowpathsprovidedinthe extremeposition.Forexample,athreeposition,fourwayvalvehastwoextreme positionsandacenter(neutral)position.Eachoftheextremepositionshastwoflow paths. 28.PoppetValve.TheoperationofasimplepoppetvalveisshowninFigure23. Thevalvehasamovablepoppetthatclosesagainstavalveseat.Pressurefromthe inletholdsthevalvetightlyclosed.Aslightforceappliedtothepoppetstemopensthe valve.ThepoppetstemusuallyhasanOringsealtopreventleakage.Onsomevalves, poppetsareheldintheseatedpositionbysprings.

Outlet Valve seat

Inlet

Poppet

Closed view

Open view

Figure23.Simplepoppetvalve 29.SlidingSpoolValve. a.Aslidingspoolvalveisalsoknownasapistontypevalvebecauseithasa pistonwithtwoinnerareasofequalsize.Pressurefromtheinletportactsequallyon bothinnerareasregardlessofthepositionofthespool.Theportsaresealedbya machinefitbetweenthespoolandvalvebodyorsleeve.

EN 5260

2-6

b.Thespoolinaslidingspoolvalveisclassifiedbasedontheflowconditions createdwhenitisintheneutral(normal)position.Forexample,aclosedcenterspool blocksallvalveportswhenitisintheneutralposition.Anopencenterspoolopensall valveportswhenitisintheneutralposition.Closedcenterandopencentervalvesare twoofmanydesignsusedforslidingspool,directionalcontrolvalves. c.TheslidingspoolvalveisshowninFigure24.Duringoperation,thevalve elementslidesbackandforthtoblockoruncoverportsinthehousing.

Outlet port blocked by piston

Spool shifted to left

Closed to flow Closed view

Port open

Spool shifted to right

Open to flow Open view

Figure24.Slidingspoolvalve

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EN 5260

210.TwoWayValves.Twowayvalvesareusedtocontrolthedirectionoffluidflow inahydrauliccircuit.Thesevalvesareusuallytheslidingspooltype.Asthespool movesbackandforth,itallowsorpreventstheflowoffluidthroughthevalve. 211.FourWayValves.Fourwayvalvesalsocontrolthedirectionoffluidflowina hydrauliccircuit.Thefluidmovementcontrolsthedirectionofaworkcylinderorthe rotationofafluidmotor. a. Fourwayvalvesareusuallytheslidingspooltype.Theyhavearectangular castbody,aslidingspool,andacontrolleverforpositioningthespool.Thespoolis precisionfittedtoaborethroughthelongitudinalaxisofthevalve'sbody.Thelandsof thespooldividetheboreintoaseriesofseparatechambers.Portsinthevalve'sbody leadintothesechambers.Thepositionofthespooldetermineswhichportsareopento eachotherandwhicharesealed.Portsthataresealedinonepositionmaybe interconnectedinanotherposition. b. Fourway,directionalcontrolvalveshavefourportsapressure,areturn (exhaust),andtwoworking.Thepressureportconnectstothepressureline(inlet),the returnportconnectstothereservoir(outlet),andthetwoworkingportsconnecttothe actuatingunit.

PARTC:CONTROLVALVEREPAIR
212.General.ThecontrolvalveonaJ.I.CaseScoopLoaderModelMW24Cenables theoperatortodirecttheflowofhydraulicfluidtothecylindersthatoperatetheloader. Itservesacombinationofpurposesandfunctionsasapressurerelief,directional control,andoverloadcheckvalve.Thevalvehasthreeoperatingspoolsasshownin Figure25.

EN 5260

2-8

1 2 3

Figure25.Controlvalve a.Theupperspool(1)controlstheliftcircuit,thecenterspool(2)controlsthetilt circuit,andthelowerspool(3)controlstheclamcircuit. b.Whenthespoolsareintheneutralposition,oilflowfromthepumpisdirected throughthevalvetotheoutletportandreturnedtothereservoir.Whenthespoolis movedbythecontrollinkage,thebypassisclosedandoilflowsthroughthespoolload checkvalvetothedesiredcylinderport.Atthesametime,aportattheoppositeendof thecylinderisopenedtoallowoiltoflowtothecontrolvalve'soutletport. 213.DisassemblingtheControlValve.RefertoFigure26,andcompletethe followingstepstodisassemblethecontrolvalve:

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EN 5260

8 10
10

6
10

5 4
10

9
10

10

11
10

12 13 15 0
10 10

14
10

10

17 19
10 10

16 06
10

21 23 7
10 10

20 10
10

22 24 10
10 10

10

18
10

28 27
10 10

26
10

25
10

29
10

32 31 8
10 10

1 3 2 2 1
10 10

30
10

33
10

10

1. Seal assembly 2. Wiper 3. O-ring ring 4. 5. 6. 7. 8. 9. Screws (4) Contact wires Connector Setscrew Retaining ring Cap

10. O-ring 11. Coil 12. Spacer 13. 14. 15. 16. 17. 18. Screw Washer Coil Washer Stud Detent housing

19. Washer 20. Spring seat 21. Spring 22. 23. 24. 25. 26. 27. Spring Spring seat Washer Retainer O-ring Retainer

28. O-ring 29. Spool 30. O31. Spool eye 32. O-ring 33. Sleeve

Figure26.Controlvalve

EN 5260

2-10

NOTE:Beforebeginningthedisassemblyprocess,cleanthevalve'sexterior andportswithcleaningcompoundsolventanddrythemthoroughly. a. Placethecontrolvalveassemblyonacleanworkbench. b. Useanopenendwrenchtoloosenandremovethesealassembly(1). c. Useascrewdrivertoremovethewiper(2)fromthesealassembly(1).Discard thewiper(2). d. RemovetheOring(3)fromthesealassembly(1).DiscardtheOring(3). WARNING Donotovertightentheviseasitwillcausedamagetothecontrolvalve body. e. Placethecontrolvalveassemblyinasoftjawedvise. f. Loosenthedetenthousing(18). g. Installarodorsmallprybarinthespooleye(31). h. Loosenandremovethefourscrews(4). i. Pulltheconnector(6)upfromthecap(9)justenoughtogainaccesstothewires solderedtothecontacts.Tagandunsolderthewiresfromtheconnector(6)contacts. Removetheconnector(6). j. Removethesetscrew(7). k. Useascrewdrivertoremovetheretainingring(8).Removethecap(9). l. RemoveanddiscardtheOring(10)fromthecap(9). NOTE:Onsomeunits,tapemaybeusedtoholdthecoils(11and15)and spacer(12)together,preventingtheirremoval.Ifremovalisnotpossible, disregardparagraph213(m)andgotoparagraph213(n). m.Removethecoil(11)andthespacer(12)fromthedetenthousing(18). WARNING Holdthecoil(11)againstthespring(21)tensionwhenlooseningthescrew. Failuretodosocouldresultinseriousinjuryfromflyingparts.

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EN 5260

n.Loosenthescrew(13)withthecoil(11)againstthespring(21)tension. Iftapeisaroundthecoils(11and15),andthespacer(12)andthescrew (13)havenotbeenloosenedfromthestud(17),removethecoils(11and 15),thespacer(12),thescrew(13),thewashers(14and16),thestud(17), thewasher(19),thespring(22),andthewasher(24)asanassemblyandgo toparagraph213(q). Iftapeisaroundthecoils(11and15),thespacer(12),thescrew(13),and thewashers(14and16)asanassembly,gotoparagraph213(o). Iftapeisnotused,loosenandremovethescrew(13),thewasher(14),and thestud(17)asanassembly.Ifthescrew(13)isloosenedfromthestud (17),removeonlythescrew(13)andthewasher(14)andgotoparagraph2 13(s).

o. Removeanddiscardthetapesecuringthecoils(11and15)andthespacer (12). p. Tagandunsolderthecoil(11and15)wires. q. Separatethecoils(11and15)andthespacer(12).Ifthescrew(13)wasnot loosenedfromthestud(17),andthewasher(24)andthespring(22)wereremovedwith thestud(17),workthewasher(24)fromthestud(17)andremovethespring(22)and thewasher(19).Removethescrew(13)andthewasher(14)fromthestud(17). r. Removethecoils(11and15)andthespacer(12).Ifthescrew(13)wasloosened fromthestud(17),thespringseat(20),thesprings(21and22)andthewasher(24); andifscrew(13)wasloosenedfromstud(17),andspringseat(23),gotoparagraph2 13(w). s. Removethecoil(15),thewasher(16),andthedetenthousing(18). t. Removethewasher(19)andthespringseat(20)fromthespring(21). u. Removethetwosprings(21and22),thespringseat(20),andthewasher(24). v. Unscrewandremovethestud(17)fromthespool(29)ifitisnotalready removed. w. Removetheretainer(27)andtheOrings(26and28)fromthespool(29)bore. DiscardtheOrings(26and28).

EN 5260

2-12

x. Removetheretainer(27)andtheOring(28)fromthespool(29)bore.Discard theOring(28). NOTE:Cleanallmetalpartsincleaningcompoundsolventandletthemair dry.Donotusecompressedair. 214. InspectingandRepairingtheControlValve.RefertoFigure26,page29, andcompletethefollowingstepstoinspectandrepairthecontrolvalve: a.Inspectthecontrolvalvebodyforcracks,breaks,orotherdamage.Inspectthe spoolboreforgrooves,deepscratches,orothervisiblewear.Ifdamageisdiscovered, replacetheentirecontrolvalvebody. b.Inspectthespool(29)forgrooves,deepscratches,orothervisiblewear.Replace thespoolifnecessary. c.Thefreelengthofthespring(22)shouldbe2.63inches.Useaspringgaugeand checkthattheforcerequiredtocompressthespring(22)to1.375inchesis13.5to16.5 pounds.Theforcerequiredtocompressthespring(22)to0.938inchshouldbe18to22 pounds.Replacethespring(22)ifthefreelengthortheforcerequiredtocompressitis notasspecified. d.Thefreelengthofthespring(21)shouldbe4.25inches.Useaspringgaugeand checkthattheforcerequiredtocompressthespring(21)to2.25inchesis27to33 pounds.Theforcerequiredtocompressthespring(21)to1.375inchesshouldbe38to 48pounds.Replacethespring(21)ifthefreelengthortheforcerequiredtocompress itisnotasspecified. e.Connectamultimeteracrossthecoil(11)wires.Themultimetershouldindicate a45to65ohmsresistance.Connectamultimeteracrossonewireofthecoil(11)and itsmetalhousing.Themultimetershouldindicateinfinity(opencircuit).Repeatthe multimetertestonthesecondcoilwireanditsmetalhousing.Again,thereading shouldindicateinfinity.Replacethecoilifthemultimeterreadingisnotasspecified. Repeatparagraph214(e)onthesecondcoil(15). f.Inspecttheremainingpartsforcracks,breaks,deformation,distortion,and damagedorstrippedthreads. 215. ReassemblingtheControlValve.RefertoFigure26,page29,andcomplete thefollowingstepstoreassemblethecontrolvalve: NOTE:Coatallvalvepartsandbodyboreswithengineoilbeforebeginning thereassemblyprocess.

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EN 5260

a.Placearodthroughoneholeinthespool(29).Placethespool(29)inasoft jawedvise. b. Installthesleeve(33)onthespool(29),sleeveshoulderup. c. Placeasmallamountofretainingcompoundonthethreadsofthespool(29). d.InstallanewOring(32)onthespooleye(31).Installthespooleyeinthespool (29)andtightento19to21footpounds.InstallanewOring(30)inthespoolboreof thecontrolvalvebody. e.Lubricatethespool(29)anditsborewithcleanlubricatingoil.Installthespool (24)initsbore. f.Installarodoraprybarinthespooleye(31). g.Placethecontrolvalveassemblyinasoftjawedvise. h.InstallanewOring(28)intheboreonthecontrolvalvebody.Installthe retainer(27)inthebore. i.PlaceanewOring(26)onthespool(29)andinstalltheretainer(25). j. Placethewasher(24)andthespringseat(23)onthespool(29).Makesurethat thewasher(24)isinthespringseat(23)hole. k. Installthetwosprings(21and22)andthespringseat(20).Installthewasher (19)inthespringseat(20). l. Installthedetenthousinginthecontrolvalvebody.Tightenthedetenthousing to30to32footpounds. m.Installthewasher(16). n. Installthecoil(15)andfastentheleadendstogetherwithtape. o. Applyasmallamountofretainingcompoundtothestud'sinternalthreadsifthe screw(13)andstud(17)wereseparated.Installthewasher(14),screwonthestud, andtightento10to12footpounds. p. Applyasmallamountofretainingcompoundtothestud(17)threads.Install thestud(17)inthedetenthousing(18).

EN 5260

2-14

q. Pushdownandturnthescrew(13)toinstallthestud(17)inthespool(29). Tightento19to21footpounds. r. Installthespacer(12)inthedetenthousing(18). s. Installthecoil(11). t. InstallanewOring(10)onthecap(9). u. Feedtheleadsfromthecoils(11and15)throughthecap(9)hole.Installthecap inthedetenthousing(18),aligningthesetscrew(7)holewiththeholeinthedetent housing. v. Installtheretainingring(8)andthesetscrew(7).Tightenthesetscrew(7). w. Solderthecoil(11and15)leadstotheconnector(6)usingarosincoresolder. Solderoneleadfromeachcoil(11and15)tocontactB(5)inconnector(6).Solderthe secondleadfromthecoil(15)tocontactA(5)inconnector(6).Solderthesecondlead fromthecoil(11)tocontactC(5)inconnector(6). x. Positiontheconnector(6)onthecap(9).Installandtightenthefourscrews(4). y. Removetherodortheprybarfromthespooleye(31). z. InstallanewOring(3)inthesealassembly(1). aa.Placethesealassembly(1)inahydraulicpress,threadedenddown.Place thewiper(2)onthesealassembly.Usea13/4inchdiameterrodtopressthewiper(2) intothesealassembly(1)untilthewiperisflushwiththetopofthepump. bb.Installandtightenthesealassembly(1). cc. Installthecontrolvalveassembly. 216.TestingandAdjustingtheControlValve.Testthecontrolvalveassemblyby observingitduringoperation.Withtheoilattherecommendedoperatingtemperature andtheenginerunningatafastidle,checkthetimerequiredtoraisetheemptybucket onthescooploaderfromthegroundtoitshighestraisedposition.Thisshouldtake approximately6seconds.Ifittakesmorethan6secondsforthebuckettoraise,ensure thatthe ReservoirisfilledtotheproperoillevelasstatedintheappropriateTM. OilisthetypespecifiedintheappropriateTM.

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Suctionlineisunrestrictedandthestrainerisclean. Scooploaderisoperatingatthecorrectfastidlespeed,asstatedinthe appropriateTM. Powersteeringpumpandthedemandvalveareoperatingproperly.

NOTE:Repeatthistestwithaloadedbucket.Iftheliftingtimeisgood (6seconds)withanemptybucketbutslowwithaloadedbucket,checkthe cylinderpacking,mainpressurereliefvalve,andhydraulicpump.

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LESSON2 PRACTICEEXERCISE
Thefollowingitemswilltestyourgraspofthematerialcoveredinthislesson.Thereis onlyonecorrectanswerforeachitem.Whenyouhavecompletedtheexercise,check youranswerwiththeanswerkeythatfollows.Ifyouansweranyitemincorrectly, studyagainthatpartwhichcontainstheportioninvolved. 1. Valvesareratedbytheir__________________,pressurecapabilities,andpressure dropversusflowcapabilities. A. Function B. Construction C. Capacity D. Size 2. ________________________occurswhenpressureononesideorendofaball, poppet,orspoolisopposedbyaspringontheoppositeend. A. Leveloperation B. Restrictedoperation C. Hydraulicbalance D. Definiteflow 3. Whatisthemostcommontypeofpressurecontrolvalve? A. Relief B. Check C. Plunger D. Gate 4. Thedifferencebetweenfullflowpressureandcrackingpressureiscalled ________. A. Override B. Spoolvalve C. Pressuredrop D. Pilotstage 5. Whichvalvemaybeoperatedmanually,mechanically,electrically,hydraulically, orincombination? A. Poppet

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B. Rotaryspool C. Closedcenter D. Slidingspool 6. Theslidingspoolvalveisalsoknownasthe__________typevalvebecauseithas a_____________withtwoinnerareasofequalsize. A. Plunger B. Piston C. Sleeve D. Poppet 7. HowmanyspoolsareinthehydrauliccontrolvalveonaJ.I.CaseModelMW24C scooploader? A. Two B. Three C. Four D. Five 8. Whentestingthecontrolvalve,howmanysecondsshouldittakeascooploaderto liftanemptybucket? A. B. C. D. 4 6 8 10

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LESSON2 PRACTICEEXERCISE ANSWERKEYANDFEEDBACK

Item 1.

CorrectAnswerandFeedback D.Size Valvesareratedby...(page22,Introduction) C.Hydraulicbalance Hydraulicbalanceoccurswhen...(page22,para21b) A.Relief Thereliefvalveisthemostcommon...(page23,para23a)

2.

3.

4.

A.Override Thedifferencebetweenfullflowpressure...(page23,para22b) D.Slidingspool Theslidingspoolvalve...(page26,para27a) B.Piston Theslidingspoolvalveis...(page26,para29a) B.Three Thevalvehasthree...(page28,para212) B.6 Thisshouldtakeapproximately...(page214,para216)

5.

6.

7.

8.

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APPENDIXA LISTOFCOMMONACRONYMS

C F ACCP ACE AIPD AMEDD APO ATTN AUTOVON AV AWR coml cont'd DED DETC dia DINFOS DOD

degreesCelsius degreesFahrenheit ArmyCorrespondenceCourseProgram armoredcombatearthmover ArmyInstituteforProfessionalDevelopment ArmyMedicalDepartment ArmyPostOffice attention automaticvoicenetwork automaticvoicenetwork answerweightreference commercial continued dieselenginedriven DistanceEducationandTrainingCouncil diameter DefenseInformationSchool DepartmentofDefense

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DSN EM FM ft GPM HSTRU ICE in IPD JFK lb lbft lbin LO MI mil MOS NSN para psi RCOAC reg

DefenseSwitchedNetwork engineeringmanual fieldmanual foot(feet) gallon(s)perminute HydraulicSystemTestandRepair InterserviceCorrespondenceExchange inch(es) InstituteforProfessionalDevelopment JohnF.Kennedy pound(s) pound(s)perfoot pound(s)perinch lubricationorder middleinitial military militaryoccupationalspecialty nationalstocknumber paragraph pound(s)persquareinch ReservedComponentOfficer'sAdvancedCourse regulation

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RYE SGT SSN SSN STP TM TRADOC US VA vol

retirementyearending sergeant socialsecuritynumber specificationserialnumber soldiertrainingpublication technicalmanual UnitedStatesArmyTrainingandDoctrineCommand UnitedStates Virginia volume

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APPENDIXB RECOMMENDEDREADINGLIST
Thefollowingpublicationsprovideadditionalinformationaboutthematerialinthis subcourse.Youdonotneedthismaterialtocompletethissubcourse. FM5499.Hydraulics.1August1997. STP562B1SM.Soldier'sManual,MOS62B,ConstructionEquipmentRepairerSkill Level1.25September1990. STP562B24SMTG.Soldier'sManualandTrainer'sGuide:MOS62B,Construction EquipmentRepairer(SkillLevel2/3/4).15October1990. TM52350262201.UnitMaintenanceManualVol1of2forArmoredCombat Earthmover(ACE),M9(NSN2350008087100)(ThisItemisIncludedon EM0035).3January1997. TM52350262202.UnitMaintenanceManual,Vol2of2forArmoredCombat Earthmover(ACE),M9(NSN2350008087100)(ThisItemisIncludedon EM0035).3January1997. TM5241023720.UnitMaintenanceManualforTractor,FullTracked,LowSpeed: DED,MediumDrawbarPull,SSNM061,TractorWithRipper,(NSN241001223 0350)TractorWithWinch,(2410012237261)TractorWithRipperandWinterized Cab,(2410012532118)TractorWithWinchandWinterizedCab,(241001253 2117)(ThisItemisIncludedonEM0119).30March1993. TM5241023734.DirectSupportandGeneralSupportMaintenanceManualfor Tractor,FullTracked,LowSpeed:DED,MediumDrawbarPull,SSNM061 TractorWithRipper,(NSN2410012230350)TractorWithWinch,(241001223 7621)TractorWithRipperandWinterizedCab,(2410012532118)TractorWith WinchandWinterizedCab,(2410012532117)(ThisItemisIncludedonEM0119). 30March1993. TM5380526220.OrganizationalMaintenance,Loader,ScoopType,DED,4x4, ArticulatedFrameSteer,21/2CubicYard(J.I.CaseModelMW24C)(NSN3805 011504814)(ThisItemisIncludedonEM0115).1September1987. TM5380526234.DirectSupportandGeneralSupportMaintenanceManualFor Loader,ScoopType,DED,4x4,ArticulatedFrameSteer,21/2CubicYard(J.I. CaseModelMW24C)(NSN3805011504814)(ThisItemisIncludedonEM0115). 1September1987.

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APPENDIXC METRICCONVERSIONCHART
ThisappendixcomplieswithcurrentArmydirectiveswhichstatethatthemetric systemwillbeincorporatedintoallnewpublications.TableC1isaconversionchart. TableC1.Metricconversionchart
US Units Inches Inches Inches Square inches Cubic yards Gallons Ounces Pounds Pounds Metric Units Multiplied By Length 2.54 0.0254 25.4001 Area 6.4516 Volume 0.7646 3.7854 Weight 28.349 453.59 0.45359 Multiplied By Length 0.3937 39.37 0.03937 Area 0.155 Volume 1.3079 0.2642 Weight 0.03527 2.2046 Equals Metric Units Centimeters Meters Millimeters Square centimeters Cubic meters Liters Grams Grams Kilograms Equals US Units

Centimeters Meters Millimeters Square centimeters Cubic meters Liters Grams Kilograms

Inches Inches Inches Square inches Cubic yards Gallons Ounces Pounds

C-1

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APPENDIXDPUBLICATIONEXTRACTS
TM5241023734,30March1993. Usetheabovepublicationextractstotakethissubcourse.Atthetimewewrotethis subcourse,thiswasthecurrentpublication.Inyourownworksituation,alwaysrefer tothelatestofficialpublications.

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