Series 51 and 51-1

Failure Analysis
Lines
cut into
end cap

A “symptom” of block/segment tipping is a line/lines cut into the end cap

by the edge of the valve segment when it tips up. Block/segment tipping
can be caused by over speed of the shaft assembly.
A twisted synchronizing shaft can also cause the block/segment to tip up
away from the end cap.
Rubbing
on pistons

Rubbing marks on the ball end of the piston stems are from the block bores.
When the block tips from centrifugal force, caused by over speed, the edge
of the bores can / will rub against the piston stems.
Rubbing
on pistons

A twisted synchronizing shaft can also cause the block/segment to tip up away from
the end cap. The timing between the block and the pistons is off enough that the
pistons rub against the block bores and cause the block/segment to tip up. The rubbing
marks are slightly higher on the piston stems in this case
Damage at
bore edge

When the pistons rub against the top edge of the block bores, damage to the
bores can occur. Usually this damage is minor.
 Twisting of the synchronizing shaft can occur when a sudden rotational
Twisted shock overload is induced through the motor output shaft. During the
synchronizing overload, twisting is caused by the inertial force of the cylinder block
against the synchronizing shaft .
shaft

A twisted synchronizing shaft can / will cause the timing between the
block and pistons to be off enough to cause the block/valve segment to
tip up away from the end cap.
Broken
rollers

Synchronizing shaft rollers, broken after coming off the sync. shaft. The
rollers can/will come off when the block tips from over speed. The block tips
to a bigger angle with the synchronizing shaft and the rollers come out of the
raceways in the block. The centrifugal forces of the block turning at excess
speed makes it tip. When the block tips it causes the valve segment to tip
away from the end cap.
A twisted synchronizing shaft can also cause the block/segment to tip up away
from the end cap.
Damaged
synchronizin
g shaft

The synchronizing shaft will be damaged after a roller or rollers come off.
The end of the leg now hits against the roller raceway in the block.
Damaged
block
raceway

This damage to a block raceway for a synchronizing shaft roller, is caused when
a roller starts to come off the synchronizing shaft leg then comes down on the
edge of the raceway. The rollers can / will come off the sync. shaft legs when
the block tips at a bigger angle away from the sync. shaft.
Scored
piston

Scuffing on pistons is caused by loss of lubrication. Loss of lube. can be caused by; to
low viscosity of the oil from over heat or just to thin of oil, improper oil (poor
lubricating qualities), or over speed. The piston movies so fast back and forth in its bore
that it losses its oil film. The piston land wears down enough to allow the ring (at least
½ of it) to come out of its groove and break. The pieces of the ring usually end up in the
motor case or in the drain line. But not always, sometimes pieces can go into the system
loop and cause damage.
Scored
block
bores

Scuffing in the block bores is usually at the outer side of the bore. This is
because centrifugal force is throwing the pistons out from center. If a piston
or pistons are scuffed, the block bore will also be scuffed. The rough surface
of the block bore is what scuffs the piston and removes enough material to
let the ring come out of its groove.
Damaged
bearing
plate

If a piece of piston ring gets into the system loop, it can cause sever damage. The
pump valve plate and block face may also look like this.
Contamination

Sever scoring from large particle contamination.

Broken
spindle

A broken spindle may be caused by the servo piston and valve segment moving
to fast and stopping against the minimum displacement stop screw with excess
force. Check for improper or missing orifices. Or the spindle may not have the
proper hardness or material.
Excess force on
valve segment

The valve segment hitting the min. displacement

stop screw with excess force may cause the
spindle socket to break. Check the edge of the
segment for heavy denting, should be only a light
mark here.
 Interference between
servo piston and
spindle (51-1)

If a servo piston does not have the proper chamfer,

it can have an interference fit with the valve
segment spindle.
A light mark on the spindle will show this
interference (possibly on both sides). This
interference can lift the valve segment off the end
cap while the servo piston is moving.
Improper
chamfer in servo
piston 51-1

If the chamfer in the servo piston is to

narrow it may cause an interference with
the valve segment spindle.

Proper width Improper width

 Broken
shaft

A broken shaft like this is caused by a bending fatigue.

In this case the motor was not in alignment with the gear-
box it was attached to. Two of the mounting screws
bottomed out before pulling the flange up tight against
the gear-box. Small “beach” marks on the end of the
shaft show that the shaft broke a little at a time.