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Cerrar SIS
Pantalla anterior
i07370218
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Introduction
Table 1
Revision Summary of Changes to SEBF9307
23 Added new serial number prefixes
22 Added new serial number prefixes
21 Added new serial number prefixes.
20 Update Effectivity
19 Made correction to the caption in Illustration 242. Updated effectivity
© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat Dealersonly.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law. Information contained in this document is considered
Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to
benefit from cost reductions. Every effort has been made to provide the most current information that
is known to Caterpillar. Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication. This Reuse and Salvage
Guideline must be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the
Service Information System. To address an urgent issue, use the following resources to communicate
your request to Caterpillar Repair Process Engineering:
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• Knowledge Network
Summary
The purpose of this document is to give visual guidelines to see if piston pump and motor parts can be
used again.
When used in the same application, parts that can be used again can be expected to give normal
performance until the next overhaul.
Never install a part that this document shows cannot be used again.
During reconditioning, correct any conditions that might have caused the original failure.
Illustration 1 g02139237
Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills, and tools to perform these functions properly.
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Do not operate or perform any lubrication, maintenance, or repair of this product, until you
understand the operation, lubrication, maintenance, and repair information. Safety precautions and
warnings are provided in this manual and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or to other persons.
Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word
such as "Warning" that is shown below.
Illustration 2 g02662636
• Pay Attention!
• Become Alert!
The message that appears under the warning explains the hazard. The message will be written or
pictorially shown.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, a
procedure, a work method, or an operating technique that is not recommended by Caterpillar is used,
ensure that the procedure is safe for all personnel around the machine. Also ensure that the product
will not be damaged or be made unsafe by the operation, lubrication, maintenance, or repair
procedures.
All of the information, specifications, and illustrations that are in this publication are based on
information that was available at the time of publication. The following information could change at
any time: specifications, torque, pressures, measurements, adjustments, illustrations and other items.
These changes can affect the service that is given to the product. Obtain the most current and
complete information before you start any job. Caterpillar dealers have the most current information
that is available.
Safety
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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
NOTICE
References
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Table 2
References
Media
Title
Number
PECJ0003 "Cat Hand Tools and Shop Supplies"
PEGJ0075 "Cat Loctite Global Crossover List"
"Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning
SEBF9236
Components"
SEBF9238 "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240 "Fundamentals of Flame Spray for Reconditioning Components"
NENG2500 "Dealer Service Tool Catalog"
Table 4
Optional Tools
Source Description
Lapmaster International (lapmaster.com) Lapping Machine
Sunnen (sunnen.com) Convex Barrel Lap Machine
Cleaning Procedure
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Before a part is inspected, wash the part in a clean solvent made from petroleum. Wash each part
separately. If several parts are washed together, there is a possibility that the machined surface can be
damaged. Use compressed air to dry the part. Put hydraulic oil on the part to prevent rust or corrosion.
Put the part in a clean container. Use a lint-free towel to clean the part before assembly. Be sure to put
oil on all of the parts during assembly.
Inspection Procedure
Piston pump and motor parts have wear patterns that can be seen but not felt by a fingernail or pencil
lead after salvage procedure. This type of wear has no effect on the performance of the part. Unless
stated in this guideline, parts cannot be used again that have wear patterns felt with a fingernail or
pencil lead after the salvage procedure. Throughout this guideline, the fingernail or pencil lead
inspection will be used to determine if a part can be used again.
Use 4/0 emery polishing paper. Refer to Tool Catalog, PECJ0003, "Cat Hand Tools and Shop
Supplies". Put the emery paper on a ground surface plate ( 7B-0337 Plate) so the paper is smooth. Do
not use any other surfaces.
Wash the part in a clean solvent. Let the part dry at room temperature. Put hydraulic oil on the part
and then put the part in a clean container.
1. Wet the emery paper with a clean solvent made of a petroleum base.
2. Place the part on the emery paper with the surface to be "touch lapped" on the paper.
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Illustration 3 g02552199
Touch lapping procedure used on a piston slipper face.
3. Move the part in a pattern tracing out a number "8". More than ten complete number "8"
patterns is not necessary. Refer to Illustration 3.
4. Wash the part in a clean solvent. Let the part dry at room temperature.
5. Put hydraulic oil on the part, and then put the part into a clean container.
NOTICE
When you handle or put pump and motor parts in storage, care must
be taken to prevent damage to the machined surfaces.
Illustration 4 g02552218
Apply compound at several points on sealing surface.
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Use Grade A silicon carbide lapping compound that is suspended in a paste type lubricant. Clover
Compound, Thixogenous-Greasemix, or an equivalent is recommended. Apply the compound to
several locations on the surface that is to be lapped. Refer to Illustration 4.
Illustration 5 g02552236
Place the port plate on top of the barrel assembly in an operating position. Apply firm pressure
downward on the port plate while sliding plate back and forth in a circular motion. At the same time,
rotate the barrel assembly. Refer to Illustration 5. After a brief time, the lapping compound will lose
lubricity (lubrication capability) and become dry. At this time, apply more compound.
When the discoloration and light scratches are removed, thoroughly clean the components to remove
lapping compound before using again. A clear solvent is recommended.
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Illustration 6 g02552237
Barrel and port plate after hand lapping.
Lapping machines are easy to operate. However, some general guidelines must be followed.
1. Check the lapping plates periodically, preferably every morning before starting production, to
ensure lap plate flatness.
2. Fill the slurry tank with a lapping vehicle. The vehicle is purchased premixed, and a lapping
compound should be added to the vehicle at a rate of 8 oz. per gallon.
3. Run the machine without parts for 4 to 6 minutes allowing the compound to mix evenly in the
vehicle.
4. Load the parts to be lapped inside the conditioning rings. The parts should be free to move
about within the ring and not packed remaining stationary.
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5. Lapping times will vary according to the severity of the flaw that is to be removed. Minor
scratches or warpage can usually be removed within 30 to 60 minutes.
c. Polish the lapped surface, using 600 grit emery paper on a 4/0 polishing stand, until
surface reflects light.
Illustration 7 g02552240
Optical flat.
A monochromatic light source and an optical flat are required to determine flatness. Refer to
Illustration 7.
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Illustration 8 g02552242
Light band pattern.
Test for flatness by observing the light, emitted from the monochromatic light head, reflecting from
the surface being checked, up through the optical flat. A series of dark bands and light spaces will be
projected. Refer to Illustration 8. The dark bands are not light rays, but show where interference is
produced by reflections from the test piece in the optical flat. Inspect the light bands for straightness.
If the bands are straight and parallel, the surface is flat. If the bands are curved, the surface is not flat
but may be flat enough for your particular needs.
Illustration 9 g03349220
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Illustration 10 g03349242
(1) Piston Shaft
(2) Barrel Assembly
(3) Piston Shaft Assembly
(4) Piston Retainer
(5) Link-Type Piston Assembly
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Illustration 11 g03351822
Class sizes of piston sets are identified by the marks engraved on top. Example shown in Illustration
11 is class size II. Refer to Special Instruction, SEBF8113, "Specifications for L-Series Reusable
Hydraulic Pump and Motor Components".
Illustration 12 g03351829
Pintle shaft is matched to a specific piston drive shaft and must not be interchanged with other piston
shafts. Refer to Illustration 12.
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Illustration 13 g03351836
Spherical ball is ground to match a specific shaft assembly and cannot be interchanged. Refer to
Illustration 13.
Piston Slipper
Check to see if the slipper will move by hand on the piston ball. The slipper can feel loose or tight but
must move in all directions without binding. If binding is felt, do not use the piston assembly again.
Note: Be sure that the lubrication port is not plugged. Use a wire to check the hole.
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Illustration 14 g03398342
Piston slipper with shallow grooves on the side of slipper.
Use Again
Illustration 15 g03398371
(1) Bearing Area
(2) Lubrication Port
(3) Balance Land
(4) Piston
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Note: Polishing marks on the new faces are normal. These marks cannot be felt with a fingernail or
pencil lead.
Slipper Face
Check to see if the slipper will move by hand on the piston ball. The slipper can feel loose or tight but
must move in all directions without binding. If binding is felt, do not use the piston assembly again.
Note: Be sure that the lubrication port in not plugged. Use a wire to check the hole. Refer to
Illustration 15.
Illustration 16 g03351926
Piston assembly with scratches to bearing surfaces. Use the "Touch Lapping Procedure"
Use Again - Only if reuse criteria are met.
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Illustration 17 g02639836
Piston assembly after touch lapping procedure. Not all scratches and erosion were removed.
Do Not Use Again
Illustration 18 g03354568
Piston assembly with large "pop outs" and metal embedded in bearing area.
Do Not Use Again
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Illustration 19 g03354582
Slipper with smeared face.
Do Not Use Again
Illustration 20 g02653537
Piston assembly with foreign material in the slipper face.
Do Not Use Again
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Illustration 21 g03398441
Piston assembly with discoloration on the slipper face. Use the touch lapping process.
Use Again
Illustration 22 g02640056
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No discoloration can be seen on the balance land or bearing area after touch lapping procedure.
Use Again
Illustration 23 g03398617
Piston assembly with fine scratches on the slipper face. Use the touch lapping procedure.
Use Again
Illustration 24 g03398619
Piston assembly after touch lapping procedure. Scratches on the balance land cannot be felt with fingernail or lead pencil.
Use Again
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Illustration 25 g03398621
Piston assembly with grooves that are not deep on the side of the slipper.
Use Again
Illustration 26 g02505556
Piston slipper severely damaged due to cavitation and contamination.
Do Not Use Again
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Illustration 27 g02653656
Slipper face with erosion in the balance land.
Do Not Use Again
Illustration 28 g02653699
Slipper face with rolled edge.
Do Not Use Again
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Illustration 29 g02653777
Corners of piston slippers must be square.
Illustration 30 g02653838
Slipper feet should freely rotate.
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Illustration 31 g02640796
Measurement of the slipper foot thickness.
Note: The slipper foot thickness of all the pistons from a single pump or motor must be measured.
No pits, scratches, nicks, or indentations are allowed which extend across more than 50% of the width
of the sealing land surfaces. "Above the surface" irregularities are not allowed. Rework by touch or
power lapping.
Illustration 32 g02641697
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Illustration 33 g03125140
Check the end play of the piston assembly with a V-block, two other pistons, a dial indicator and a
flat plate. Put the piston to be measured in the V of the V-block on the slipper back faces. Put the dial
indicator into position with the pointer on the end of the piston. Refer to Illustration 32. Push down on
the piston and set the dial indicator at zero. Pull up on the piston. Refer to Illustration 33. If the
dimension measured is more than the piston assembly end play allowance, the piston assembly cannot
be used again.
Illustration 34 g02713192
(1) Piston Ball
(2) Piston Shaft
(3) Ring grooves for piston rings
Groove or seizure marks on piston ball or piston shaft are not acceptable. If this damage is present, the
parts must be replaced. Breakouts or other damage to ring groove are not allowed.
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Seizure marks on the piston ball are indications of dirt. Seizure marks on the piston shaft are
indications of exceeding the permissible maximum speed of the motor. If grooves can be felt, the
hydraulic fluid may be contaminated. Dull contact points are acceptable.
Illustration 35 g03351940
Ball head with scratches that cannot be felt with a pencil lead or fingernail.
Use Again
Illustration 36 g02714077
Pistons with slight wear on tapered shaft that cannot be felt with a pencil lead or fingernail.
Use Again
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Illustration 37 g03351942
Piston rings with slight wear that cannot be felt with a pencil lead or fingernail.
Use Again
Illustration 38 g03351944
Wear on piston rings (sealing surface) that can be felt with a pencil lead or fingernail.
Do Not Use Again
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Illustration 39 g03351947
Broken piston ring.
Do Not Use Again
Illustration 40 g03289176
Clearance between the piston rings and the piston grooves.
Clearance, measured with a feeler gauge, should not exceed 0.10 mm (0.004 inch). The piston rings,
and possibly the piston, must be replaced if clearance is exceeded.
Wear on the thickness of the piston rings is a result of fine contamination in the hydraulic fluid. In
addition to wear on the piston ring, wave-shaped marks can normally be found on the control surface
of the control lens.
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Illustration 41 g03351948
Pistons with scratches that can be felt with a fingernail or pencil lead.
Do Not Use Again
Illustration 42 g03351950
Piston with metal flakes or scratches that can be felt with a fingernail or pencil lead.
Do Not Use Again
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Illustration 43 g03355671
Piston assembly with blue discoloration on the piston.
Do Not Use Again
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Illustration 44 g03355672
Piston assembly with gray bands on the piston.
Use Again
Illustration 45 g03351952
Piston assembly with discoloration and scratches that cannot be felt with fingernail or lead pencil.
Use Again
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Illustration 46 g03351954
Piston exposed to severe contamination.
Do Not Use Again
Illustration 47 g03355704
Arrow points to a phenolic filler that is loose and chipped around the edge.
Do Not Use Again
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Illustration 48 g03355713
An arrow points to a phenolic filler that is loose or protrudes from barrel of piston.
Do Not Use Again
Illustration 49 g02664358
Piston filler has erosion.
Do Not Use Again
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Illustration 50 g03356371
Piston that has lost the slipper.
Do Not Use Again
Center Pin
Illustration 51 g02713158
(1) Spring plate impression on the bottom of the center pin
(2) Ball head
(3) Center pin shaft
Center pin should have no grooves or traces of seizure on the ball head. Small or light grooves on the
circumference of center pin shaft are acceptable.
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A spring plate impression does not require replacement of the center pin. However, the impression
indicates:
• Separation (lift-off) of the barrel from the port plate. Separation can result from insufficient oil
supply (cavitation) in reverse mode.
• The rotary group was not pulled back against the retaining ring after inserting into the housing.
• When fitting the motor to the gear box, the drive shaft was pushed in, thus using up all of the
end-play.
Illustration 52 g02713176
Center pin with scratches on the ball head that cannot be felt with a pencil lead. No grooves, no traces of seizure.
Use Again
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Illustration 53 g03356375
Left side of Illustration shows center pin with worn ball head. Right side shows center pin with seized ball head.
Do Not Use Again
Cup Springs
Illustration 54 g02713288
Replace cup springs if wear can be seen. Wear is indicated by polished areas.
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Illustration 55 g02713300
Assemble springs as shown.
Illustration 56 g02545463
No evidence of abrasion and scratching on mating surface for ball retainer.
Use Again
Ball Retainer
A retainer with an edge that can be felt with a fingernail or pencil lead where the contact area ends
cannot be used again.
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Illustration 57 g02664637
Retainer with normal wear and cannot be felt with fingernail or pencil lead.
Use Again
Illustration 58 g03351956
Retainer with extreme wear.
Do Not Use Again
Retainers must be free of nicks and scratches on the spherical face. Discoloration or blemishes that
cannot be felt with a fingernail or pencil lead are permitted.
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Illustration 59 g02802556
Blemishes indicated by arrow which can be seen but not felt.
Use Again
Illustration 60 g03355718
Splines extend three-quarters of the over-all height of the retainer. Retainer meets the reusability specifications.
Use Again
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Illustration 61 g03355726
Retainer chamfer matches the chamfer on the cylinder hub. Retainer meets the reusability specifications.
Use Again
Illustration 62 g03356381
Marks can be seen but not felt with fingernail or pencil lead.
Use Again
Illustration 63 g02545536
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To improve the mating surface between the shoe and ball retainers:
Seal Retainer
Illustration 64 g03355745
Markings that can be seen but not felt with a fingernail or pencil lead are acceptable.
Use Again
Wear Plate
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Illustration 65 g02645623
Wear plate with groove and wear step in the slipper seal area.
Do Not Use Again
Illustration 66 g03351964
Wear plate with heat cracks that can be felt with a fingernail or lead pencil.
Do Not Use Again
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Illustration 67 g03355754
Wear plate with a scratch across the slipper seat area that can be felt with a fingernail or lead pencil. Wear plates should
not be used again without first power lapping to remove scratches.
Use Again - After Power Lapping.
Illustration 68 g03351967
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Illustration 69 g03351972
Damage caused by piston that has lost a slipper.
Do Not Use Again
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Illustration 70 g03352244
Wear plate that is polished in the slipper seat area.
Use Again
Illustration 71 g03352247
Wear plate with scratches that cannot be felt with a fingernail or lead pencil.
Use Again
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Illustration 72 g03352250
Wear plate with discoloration on the back side.
Use Again
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Illustration 73 g03352252
Wear plate with circumferential marks on the back side.
Use Again
Retraction Bearing
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Illustration 74 g03356387
Retraction bearing with normal wear on slipper surface that cannot be felt with a fingernail or lead pencil. Use the touch
lapping procedure on the bearing before installation.
Use Again
Illustration 75 g03356393
Retraction bearing with high spots that cannot be felt with a fingernail or lead pencil. Use the touch lapping procedure on
the bearing before installation.
Use Again
Retraction Plate
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Illustration 76 g02645578
Make sure that the retraction plate is flat. Put the retraction plate on a surface plate. With fingers and
thumb, push down on opposite edges and see if any rocking motion can be felt. If rocking motion can
be felt, the plate is not flat and cannot be used again unless made flat by power lapping.
Illustration 77 g03352262
Retraction plate with wear at slipper contact area.
Use Again
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Illustration 78 g03352264
Retraction plate with wear on the outside diameter that can be felt with a fingernail or lead pencil may be salvaged by
power lapping.
Use Again - After touch lapping, if plate is flat.
Illustration 79 g02552378
Retraction plate.
Use Again - After touch lapping, if plate is flat.
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Illustration 80 g03352270
This plate shows damage from slipper "lifting". Polished or scored surfaces on the area where the spherical washer rides
is not acceptable.
Do Not Use Again
Port Plate
Illustration 81 g02711304
(1) Control Surface
(2) Contact Surface between port plate and barrel.
If there is wave-shaped wear on the control surface of the control plate, then the control surface must
be replaced. This wear can be felt with a pencil between the kidney shaped slots.
Wave-shaped run-in is a result of fine dirt particles in the pressure fluid. A high density of solid
matter particles ranging from 5 to 10 microns has the effect of lapping paste.
If both the port plate and barrel are to be replaced with new parts, then no lapping is necessary. New
parts are ground to dimension and are interchangeable. When new and used parts are paired, the
control surface must be lapped together.
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Illustration 82 g03349254
(3) Rib
(4) Seal Bands
(5) Thrust Face
(6) Port
Illustration 83 g02711370
Contact surface of the port plate must be flat and level. Inspect the levelness with a straight scale.
Use Again
Note: Use the power lapping procedure on both sides of all port plates that can be used again before
plates are installed.
A port plate that has scratches or scored marks that can be felt with a fingernail or pencil lead on the
critical surfaces or between the ports cannot be used again. Port plates that are smeared or galled on
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the critical surfaces or have blue discoloration cannot be used again. An indication of a smeared or
galled port plate is bronze colored material on the port plate surface.
Use the touch lapping procedure on port plates that have scratches or score marks that can be seen but
cannot be felt.
Note: If a port plate and a bearing plate are exchanged at the same time, then lapping is not necessary.
New spare parts are ground to dimension at the factory and are interchangeable. When matching used
parts with new parts, lapping is required.
Illustration 84 g03352273
Port plate that has erosion in the seal band.
Use Again - After power lapping.
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Illustration 85 g02645858
Port plate after the power lapping procedure.
Use Again
Illustration 86 g02646097
If power lapping removes scratches between ports and in the seal band.
Use Again
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Illustration 87 g03352275
Port plate with scratches in the seal band and thrust surface that cannot be felt with a fingernail or lead pencil.
Use Again
Illustration 88 g02646189
Port plate with a machine mark in the rib should not be used again without first power lapping.
Use Again - After power lapping.
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Illustration 89 g03356396
Port plate with smeared thrust face should not be used again without first power lapping.
Use Again - After power lapping.
Illustration 90 g03356398
Port plate with discoloration should not be used again without first power lapping.
Use Again - After power lapping.
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Illustration 91 g03352278
This port plate has light burn marks and no heat checking. Should not be used again without first power lapping.
Use Again - After power lapping.
Illustration 92 g03352279
Port plate with heavy burn marks and scoring.
Do Not Use Again
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Illustration 93 g03352282
Port plate with light scratches on seal band.
Use Again - After touch lapping.
Illustration 94 g03355792
Port plate with scratches across the seal band that can be felt with a fingernail or lead pencil.
Do Not Use Again
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Illustration 95 g03352284
Port plate with discoloration.
Use Again
Illustration 96 g03352291
Port plate with discoloration on the back side.
Use Again
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Illustration 97 g02670177
Port plate is etched in the port seal area.
Do Not Use Again
Illustration 98 g03356400
After touch lapping procedure, port plate was not possible to remove all the discoloration from the critical surfaces on the
port plate.
Do Not Use Again
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Illustration 99 g02670399
Port plate with cavitation erosion in the port area.
Do Not Use Again
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Visually inspect for cracks at the drive slot and kidneys (port openings).
On all bi-metal bearing plates, in addition to a visual inspection, use penetrant inspection to detect
cracks on the bronze surface of the plate.
Note: No steel may be visible through the bronze surface of bimetal port plates.
No pits, scratches, nicks, or indentations are allowed which extend across more than 50% of the width
of the sealing land surfaces. "Above the surface" irregularities are not allowed. Rework by touch or
power lapping.
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Use a magnetic particle inspection procedure to detect cracks. Cracks are not allowed on any surface
of the part.
Use a new port plate for field repair if the above inspection procedures cannot be exercised. This
procedure is to ensure that the port plate is not cracked or softened.
Scrap valve plates that show smearing or metal transfer on the running surface of the mating bearing
plate (barrel assembly surface if a separate port plate is not used.)
For medium-duty valve plates, use a penetrant inspection to detect cracks on the bronze surface of the
part.
Barrel Assembly
Nomenclature and Issues
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If the barrel and the port plate are both replaced at the same time, then lapping is not necessary. New
parts are ground to dimension and are interchangeable. When matching used parts with new parts,
lapping is required.
Abrasives
NOTICE
Silicon Carbide and Aluminum Oxide lapping compound are recommended for the abrasives. A
medium-fine 500-600 grit (17-14 microns) Silicon Carbide is desired for pre-lapping. A medium-fine
500-600 grit (17-14 microns) Aluminum Oxide is desired for final lapping. Silicon Carbide will
remove material from the port plate and Aluminum Oxide will help with achieving the desired surface
finish. Lapping compound can be obtained in a paste or a powder. Lapping compound should be
mixed with a light oil. Avoid water base compounds. When preparing the compound, obtain a syrup
consistency. The mixture should contain 50% oil.
Surface Examination
The following steps will provide a method to check the barrel and the port plate.
1. Examine the surface of the port plate and barrel. Look for wear if the components are used.
Light scratches can be removed by lapping. Use a sharp pencil to identify any large grooves or
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imperfections. Parts may need replaced if a pencil cannot easily run over the grooves or
imperfections.
2. Examine the surface roughness of the barrel and port plate. An average roughness of 0.1 µm
(3.9 microinches) is acceptable for the port plate. An average roughness of 0.2 - 0.3 µm
(7.8 - 11.8 microinches) is acceptable for the barrel.
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3. Scribe at least three lines using pencil lead from the center of the barrel outward. This
procedure will verify the mating of the two parts. See Illustrations 117 and 118.
4. Center the port plate on the barrel. Rotate the port plate on the barrel. Apply light pressure and
make five rotations.
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5. Remove the port plate from the barrel. Check the pencil lead marks. Record the wear pattern.
Examine the remaining length of the lead marks.
Note: 1/3 of the line should remain visible. The line should be located near the center of the
barrel. Illustration 119 indicates an unacceptable barrel. Illustration 120 indicates an acceptable
barrel. Start the procedure if any one condition exists.
Initial lapping
1. Apply a light coat of 500-600 grit (17-14 microns) Silicon Carbide lapping compound to the
port plate. Place the barrel on the port plate. Refer to Illustration 121.
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2. Rotate the barrel in a circular motion while moving the barrel around the center of the port
plate. The lapping motion should form an eccentric pattern. Refer to Illustrations 122 and 123.
An eccentric pattern is desired so that grooves are not created from a repeated motion. Apply
moderate pressure during lapping. Continue this process for 15 to 20 passes.
Note: The large cross hair indicates the center of the port plate which lies below the barrel. The
small cross hair indicates the center of the barrel on an eccentric path.
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3. Clean the barrel and the port plate with a solvent to remove the lapping compound. Repeat
Steps 1 through 5 in the "Surface Examination" section. If the desired result is not achieved,
continue lapping. Move to Step 4 once the surface is free from scratches and imperfections.
Note: Step 4 uses the file method for testing hardness. This step is not to be confused with
traditional Rockwell testing. Hardness testing files and instructions can be obtained from a local
tool supplier.
4. Perform a hardness test on the port plate using the file method. Use a hardness testing file at 65
Rockwell C. Check the lands that have been affected by lapping. The part must be replaced if
the hardness file scratches the surface. Insome cases, the amount of material removed from the
port plate may be too great to maintain the minimum material harness of 67 Rockwell C.
Proceed to the final lapping procedure if the recommended results were achieved.
Final Lapping
1. Apply a light coat of 500-600 grit (17-14 microns) Aluminum Oxide lapping compound to the
port plate. Place the barrel on the port plate.
2. Rotate the barrel in a circular motion while moving the barrel around the center of the port plate
in an eccentric pattern. Refer to Illustrations 122 and 123. An eccentric pattern is desired so that
grooves are not created from a repeated motion. Apply moderate pressure while lapping.
Continue this process for 15 to 20 passes.
3. Clean the barrel and port plate with a solvent to remove the lapping compound.
4. Apply a light coat of oil to the port plate to prevent corrosion. Place the barrel on the port plate.
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Note: Cylinder bores cannot be reworked. Therefore, if there are scratches, grooves, scoring, local
indentations, or break-out in the piston stroking area, further inspection is not needed. The barrel must
be replaced. Refer to Illustration 124.
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Dark discoloration on the control surface is not a sign of damage. However, with pittings (lead
washouts), dark discolorations are indications of overheating. Single pittings can be removed with
lapping. Interlinked pittings or breakouts and/or cracks along the core borders require replacement of
the barrel.
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1. Wash the barrel assembly and piston in a clean solvent. Use compressed air to dry off the barrel
assembly and piston.
2. Put a piston into one of the bores to the maximum depth that the piston will go into the bore
during operation.
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If no movement or only little side movement can be felt in all of the bores, the barrel assembly can be
used again. Refer to Illustration 132.
Note: Use a piston in a new barrel assembly to see how much side movement can be permitted. If
necessary, use a dial bore gauge to measure the bore diameters.
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If no wear can be seen on the barrel assembly splines, the barrel assembly can be used again. If
necessary, use two pins and an inside micrometer to measure the splines (X) as shown in Illustration
134. Put the pins 180° apart in the worn area of the splines. For barrel assemblies that have an odd
number of spline teeth, put the pins in splines as near to 180° apart as possible. Use clay or masking
tape to hold the pins in position. Refer to manufacturer specifications. Refer to Illustrations 133 and
134.
Control Lens
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If there is a wave-shaped wear on the control surface of the control lens, then the lens must be
replaced. This wear can be felt with a pencil lead between the kidney-shaped slots.
Wave-shaped run-in is a result of fine dirt particles in the pressure fluid. A high density of solid
matter particles smaller than 5 to 10 microns has the same effect as lapping paste.
If both the control lens and barrel are to be replaced with new parts, then no lapping is necessary.
New parts are ground to dimension and are interchangeable. When used and new parts are paired, the
control surfaces must be hand-lapped together.
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Miscellaneous
Drum Seal
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Side Block
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Head Assembly
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Note: The surfaces shown in Illustrations 144,145, and 146 can be lapped to a maximum of 0.38 mm
(0.015 inch). Metering notches must be altered accordingly. The bearing must be removed and
replaced.
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Bearing Ring
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If the bearing assembly is removed from the drive shaft, the nut must always be replaced. Replacing
the nut is a safety precaution.
When the drive shaft is assembled, secure the nut on the drive shaft with Loctite. Prior to assembly,
the part should be cleaned with 4C-8648 Cleaner (Hydrosolv 4110).
Once threads on the drive shaft are clean, coat the thread with Loctite primer. This primer will
improve the holding capability of the Loctite. The primer also shortens the drying time of the Loctite
to approximately 20 minutes.
Finally, coat the male threads of the drive shaft with Loctite 242. The Loctite 242 should be applied
only to the area under the nut, not to the complete length of the thread.
Cover
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Nomenclature
(1) Contact surface of the retaining ring
(2) Shaft seal seat
(3) Insertion radius for the O-ring
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Impeller
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Marks, scratches, and light rust which can be removed are allowable on the outer face of the oil seal
case.
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Piston Stops
Swash Housing
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Swashplate
Fixed Swashplates
Both the pump and motor swashplates have contact surfaces that operate against the piston slipper
faces. A swashplate whose contact surfaces has scratches or scored marks that can be felt with a
fingernail of pencil lead cannot be used again without power lapping. Use the touch lapping procedure
on a swashplate whose contact surface has scratches or score marks that can be seen but cannot be
felt.
A swashplate whose contact surface has been smeared or galled cannot be used again. An indication
of a smeared or galled contact surface is bronze-colored material on the swashplate.
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Hanger
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Check the hanger trunnion bearings for damage or abrasion markings. Replace the bearings if damage
is present. Refer to the Service Manual for the assembly procedure and the correct orientation. Refer
to Illustration 177.
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Check the machined surface of the hanger for heat cracks that can be seen and felt with a fingernail or
pencil lead. Replace the hanger if damage is present. Refer to Illustration 177.
Creep Plate
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Motor creep plate with score marks that can be felt with a fingernail or pencil lead.
Do Not Use Again
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Head
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Control Head
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Housing
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All mounting faces including the inlet and outlet port face must be reconditioned to remove all rust
and discoloration. No scratches which can be felt with a pencil lead or fingernail are allowed on the O
-ring surface of the inlet and outlet ports. Refer to Illustrations 196 and 197.
Valve Cover
Plate Side
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The inlet and outlet port faces must be reconditioned to remove all rust and discoloration. No
scratches which can be felt with a pencil lead or fingernail are allowed on the O-ring surface of the
inlet and outlet ports.
End Cover
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Surface of the end cover with no scratches or grooves, smooth, and level. Threaded holes are not damaged. Removal of
fretting or corrosion can be done by lapping.
Use Again
Bearings
NOTICE
Determine the reusability of the bearing before disassembly. No seizure, depression, or abnormal
abrasion is allowed. The bearing must not be removed from the shaft if the bearing is reusable. If the
bearing is removed, a new bearing must be installed. The press fit of the inner race on the shaft is
critical.
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Piston
Negative Flow Piston
NOTICE
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Marks can be seen but not felt with a fingernail or pencil lead.
Use Again
Pilot Piston
Servo Sleeve
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Servo sleeve with normal wear in the bore that cannot be felt with a fingernail or pencil lead.
Use Again
Servo Piston
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Actuator Piston
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Servo Inserts
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Large Piston
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Link-Type Piston
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Cartridge
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Sleeve
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Spool
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Drive Shaft
If the bearing surfaces are damaged, metal spray can be used to build up the worn area and the surface
can be machined to a "like new" condition. If this reconditioning is used and the drive shaft meets all
other reusability requirements, the shaft can be used again. oSee a thermal spray Reuse and Salvage
Guideline found in the "References" section at the beginning of this document for more information.
Both splines must meet the minimum dimension of measurement over pins to be used again.
Check for thread damage to the tapped hole in the end of the drive shaft. This threaded hole is needed
to pull the rotary group back against the retaining ring after being assembled in housing . The
threaded hole can also be used for drawing the drive element (gear) onto the spline of the shaft.
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The wear in the shaft seal area shown in Illustration 255 applies to both front and rear shafts. If
damage to the seal area is present, metal spray can be used to restore the surface to a "like new"
condition.
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Grooves in the seal area that can be felt with a fingernail, as shown in Illustration 272, can be
removed to make the part usable again.
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Note: Follow the metal spray manufacturer directions carefully in the application of metal spray to
the shaft seal area.
1. Measure the shaft outside diameter at the seal area and the shoulder radius (if present) and make
a note of each dimension.
2. Worn or damaged surfaces designated as salvable by chrome plating can also be salvaged by a
metal spray process. Metal spray is an acceptable method of restoring a surface to the original
size. Each step in the procedure is critical in achieving the desired coating bond and surface
finish. See any of the thermal spray Reuse and Salvage Guidelines found in the "References"
section at the beginning of this document for more information.
3. Grind the seal area to the diameter you measured in Step 1. The surface finish must be
0.40 to 0.80 µm (16 to 32 microinch). The wheel radius must be the same or greater than the
shoulder radius measured in Step 1.
Spline Measurement
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If the splines have a visible wear step, the shaft cannot be used again. If necessary, measure the
splines. Use two pins placed in the splines 180° apart. For shafts that have an odd number of spline
teeth, put the pins in splines as near to 180° apart as possible. Put rubber bands around the pins and
shaft to keep the pins in place. Refer to Illustrations 273 and 274. Refer to the manufacturer for
reusability specifications for the pin diameter and the use again dimension. Use an outside diameter
micrometer to measure across the pins. The crown splines must be measured at the center of the spline
for the correct measurement. If measurement is less than the dimension given by the manufacturer,
the shaft cannot be used again.
Copyright 1993 - 2023 Caterpillar Inc. Wed Oct 25 22:59:34 EST 2023
Todos los derechos reservados.
Red privada para licenciados del SIS.
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