Series D/H/M Fixed Displacement Gear Pumps Service Manual
Contents
1. FIG 10 13 Keep the parts from each pump sec tion in separate groups Fig 11 16 Remove pressure plate 13 and zw o ring 12 from the journal bores FIG 11 in the pressure plate 17 Grasp the idler and drive gear shafts 15 and 14 and lift them out of the gear plate Fig 14 FIG 16 FIG 14 20 Remove flange plate o ring 10 18 Tap the edges of the gear plate 2 pressure balance o ring 9 and with a plastic hammer to separate it nylon back up strip 8 from flange plate 1 An alternate method is to lift both plates slightly off the work surface and tap the ears of the flange plate lightly Fig 15 21 For shaft seal removal and replace ment see Seal Replacement section 22 Wash all parts in clean solvent and wipe them dry with a clean shop towel or blow dry with shop air 23 Visually inspect all parts For detailed instructions see Parts Inspection section FIG 15 19 Dowels 11 are pressed into gear plates There are eight dowels in each plate four on each side and unless gear plate 2 is replaced it is not necessary to remove them To remove the dowels use a punch and hammer to drive them out Place the punch inside of dowel and against end of dowel on opposite side and tap it out Fig 16 ASSEMBLY 24 Each TP16 pump is assembled and tested at the factory for a specific rotation Direction of rotation cannot be reversed without repla2. Hydraulics Bulletin 2630 C 1 Series D H M Fixed Displacement Gear Pumps Service Manual Effective January 2000 Supersedes December 1988 Series D H M Fixed Displacement Gear Pumps Description Hex Screws Washers Bulletin 2630 C1 1 2 3 Shaft Seal Typical Assembly Shown 4 Front Cover 5 Dowel Pin 6 V Seal 7 Gasket 8 Heat Shield 2 9 Wear Plate Repair Kits 1 ERAN Section Series Part Number Consisting of Items 12 Driven Gear Assembly p 686632K 3 6 7 8 9 10 17 13 Drive Gear Assembly Splined 745083K Viton Seals 14 Key H 706024K 3 6 7 8 9 10 16 17 15 Drive Gear Assembly Keyed 745100K Viton Seals 16 Thrust Plate H amp M Only H 696173K 3 6 7 8 9 10 16 17 17 Molded O Ring Flow Divider Seals only For 19 amp 20 18 Back Cover CH Flow Divider Pump Only H 805333K 3 6 7 8 9 10 16 17 19 Relief Valve CH Flow Divider Pump Only Power Steering Seals only For 19 amp 20 20 Flow Control H Flow Divider Pump Only NM 715567K 3 6 7 8 7 21 Back Cover 745088K Viton Seals Trouble Shooting Guide Before the pump is removed or disassembled check the following list of common troubles and remedies It could save time effort and money Trouble Probable Cause Remedy 1 Noisy Pump a Low oil supply a Fill reservoir b Oil too heavy i e viscous b Chang
3. EE p qu TT EN BE L PARTS IDENTIFICATION 7 3 T L Cover Shaft E 3 3 Strip Back Up 3 O Ring Pressure Balance O Ring Plate 2 4 5 7 8 3 3 lat Plat Dome Snap Ring Seal Retaining O Ring Pressure Plate Bore 3 4 4 3 Gear Drive Front Pump Section 4 4 e e l 5 LA nen 3 6 9 0 1 Gar ler fone owe Sou sat o 23 Adapter Mounting 1 1 1 1 L L 1 1 L 189 20 N mn 0 l 2 3 6 7 8 2 24 Washer Capscrew 25 Capscrew Adapter Mounting T N N DISASSEMBLY AND ASSEMBLY INSTRUCTIONS FOR TP16 SERIES PUMPS DISASSEMBLY 4 If your pump has a mounting adapter remove Allen head capscrews 25 l Using solvent and brush clean out washers 24 and mounting adapter side of the pump thoroughly 23 If it also a e adapter 26 behind it remove that 2 Mark all pump plates on the side also If your pump has no adapter nearest the drive shaft extension but only a standard one piece flange These marks will be used to correct disregard this step and continue ly position the plates when you with step five reassemble the pump Fig 1 5 Use a 3 4 wrench to loosen and remove nuts 22 and washers 21 Fig 3 FIG 1 3 Place the pump in a machinist vise FIG 3 Protect the pump surfaces with wood blocks or heavy cardboard placed REK 6 Remove the pump f the pump a
4. Fig 24 37 35 Install o rings 12 in pressure plate 13 With the trap in the pressure plate facing toward the discharge side place the bronze side of the plate down against the gear faces Fig 25 FIG 25 38 36 Screw studs 20 into the flange plate at this point 10 Examine bearing plate 3 carefully One side has a cast hole extending only part way through which connects with an external discharge port The plate must be installed with this side facing front gear plate 2 Fig 27 FIG 27 After you have properly identified the side of the bearing plate des cribed in step 37 lay the plate on the workbench with that side up Install bearing plate o ring 10 pressure balance o ring 9 and back up strip 8 Use clean heavy grease to hold the parts in position Fig 28 39 40 After the coupling has been installed FIG 28 Lift the plate and turn it over so the o rings just installed now face down Align the matching marks on bearing plate 3 and gear plate 2 and slide the bearing plate down the shafts until it contacts the dowels Place coupling 17 in the suction port and line it up with the splines on the drive gear shaft If the shaft extends too far into the suction port to allow the coupling to match up with the spline lift the bearing plate slightly This will allow the coupling to slide over the end of
5. If hammer is used do not drive the dowels in aggressively Tap them lightly until they are against shoulder Fig 14 Fig 14 19 With matching marks made in step 2 toward you and the four cast recesses in the outer edge of gear plate toward cover plate line up dowels Tap gear plate lightly until it is against 0 ring in cover plate Fig 15 20 Install back up ring 4 and o ring 5 as shown in figure 21 Install o ring 7 in pressure plate 8 With trap small oblong hole in pressure plate toward discharge side of gear plate and bronze side up slide pressure plate down gear bores Fig 17 Fig 17 22 Install drive gear 10 in gear bore nearest to matching mark and idler gear 11 in opp osite bore Fig 18 23 Install o ring 7 in pressure plate 8 With trap toward dis charge side and bronze side down place pressure plate down against gear faces Fig 19 24 Install back up ring 4 and NOTE Use tape to cover keyway o ring 6 in flange plate 3 Use before installing flange clean heavy grease to hold o rings to avoid nicking seal lip in grooves Fig 20 Fig 20 26 With o rings in flange plate 3 facing down and keeping plate true with shafts slide it down until it contacts dowels in gear 25 If extension end of drive plate Bump flange very lightly shaft is splined coat splines with hands or plastic hammer to with clean heavy grease to protect force the
6. in its groove 5 Install the wear plate 9 with the bronze surface against the gears and the small vent hole in line with the hole in the heat shield Press the wear plate The wear plate shall be sufficiently within the oval cavity so that it is axially retained 6 Install drive gear 13 or 15 and driven gear 12 assemblies into the front cover Apply oil to the shaft at the drive end to prevent damage to the shaft seal caused by sharp edges on the drive shaft passing through the shaft seal An oil coated shaft rotated slowly will usually cause no damage to the seal Check to see that the shaft seal lip and Spring is not pushed out by the shaft 7 Check wear plate to insure it is still seated into its oval cavity and install the center section 11 over the gears until it engages the wear plate Center section must be positioned so that the previously scribed lines on the housing exteriors are in line with those scribed on the front cover The small slot located midway between the bores should align with the small vent hole in wear plate The face containing the slot shall be in contact with the wear plate Then install dowel pins b and add a generous amount of clean oil into the gear cavities Rotate gears to distribute the oil 8 Position the thrust plate 16 on top of the gears in the center section with the bronze face toward the gears The open side should be toward the inlet 9 Install o ring 17 into its back cover face
7. plate down on dowels seal as flange plate 3 slides at the same time making sure down shaft If extension end is grease is holding o rings in keyed use a piece of tape to grooves Once plate is in position cover keyway to protect seal if keyway protection was used Rie 21 remove from shaft Fig 22 Fig 21 Eig 22 27 Coat capscrew 14 threads with clean hydraulic oil Install washers 13 on capscrews and screw them in and torque to 80 SHAFT SEAL REPLACEMENT INSTRUCTIONS ft ibs Fig 23 FOR P16 SERIES 1 Remove pump from machine Plug the suction and dis charge ports and wash the pump thoroughly If shop air is available blow all contaminants from shaft seal area 2 If only shaft seal replace ment is to be made it is not Pio 2 necessary to completely dis 18 3 assemble the pump 28 Using twelve inch wrench check 3 For adaptor equipped models to see if shaft will turn It will loosen and remove capscrews be tight but should turn free with and washers Tap the mounting a 15 lbs maximum of force on adaptor loose with a soft wrench Fig 24 hammer and slide it off the shaft Remove the flange adaptor also if one is used 4 Loosen and remove the four capscrews from the rear of the pump Hold the gear plate and valve body to gether and tap the flange plate with a soft hammer to loosen Fig 1 Fig 24 5 Slide flange plate off the eg Slide a punch of appropriate shafts and
8. sure it Is installed first and its capscrew holes are aligned with the flange plate holes Torque the capscrews to 35 1b ft Remove pump from the machine on which it is installed Plug all inlet and outlet ports and wash the pump thoroughly If shop air is available blow all contaminants from the shaft seal area If only a shaft seal replacement is to be made it is not necessary to completely dis assemble the pump Of the following procedures use those that are applicable to your pump configuration For adapter equipped models loosen and remove capscrews and washers Tap the mounting adapter loose with a soft hammer and slide it off the shaft Remove the f e adapter also if one is used This next step applies to removal of the one piece f e plate as well as to the flange plate used with mounting adapters Loosen and remove the nuts and washers from the four studs Loosen the studs from the flange plate but leave them in place in the pump It may be necessary to tap the studs while pulling on the flange plate to slide it up the shaft far enough to insert vise grip pliers between the flange plate and the gear plate in order to grasp and turn the studs Use care and don t mar the finished surfaces if you have to resort to this pro cedure Fig 1 FIG 1 After the flange plate has been freed from the studs slide it off the shafts and carefully remove and lay aside the plate o ring pressure balance o r
9. to drive them out Place driver in side of dowel and against end of dowel on opposite side and tap it out Fig 11 Ss Can Ae Pig EE 10 Tap edges of gear plate 2 with wood mallet or plastic hammer to loosen If gear plate does not move by this method lift the plates up off work bench slightly and tap the ears of flange plate 12 To complete the disassembly lightly Fig 10 follow steps 7 and 8 Fig 12 13 For shaft seal removal and replacement see seal replacement section 14 Wash all pump parts in clean solvent and wipe dry with clean shop towel or blow dry with shop alr 15 Visually inspect all parts For detailed instructions see parts inspection section ASSEMBLY INSTRUCTIONS 16 Each pump is assembled and tested for specific direction of rotation Direction of rotat ion can not be changed without changing flange 3 17 Install o ring 6 in cover plate 1 After o ring has been placed in groove spread a light coat of clean heavy grease on the o ring to hold it in place Fig 13 Fig 13 18 If for any reason gear plate 2 had to be replaced dowels 9 must be pressed into both sides of replacement gear plate before assembling it to cover plate 1 Dowels can be tapped in with hammer but it is best to use dowel guide and press Which ever method is used make sure they are straight in dowel bores If press is used do not apply rapid force on dowels
10. RESSURE DRIVE GEAR IDLER GEAR EL 32 24 34 35 36 37 38 39 40 41 42 43 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 N N RE Ho DISASSEMBLY AND ASSEMBLY INSTRUCTIONS FOR P16 PUMP DISASSEMBLY INSTRUCTIONS 3 Place pump in machinist vise Use blocks of wood or cardboard between pump and vise jaws Figa 3 1 Using solvent and brush clean outside of pump thoroughly Fig 1 Fig 4 If your pump has a mounting 2 Mark the pump plates nearest to adapter 15 remove allen drive shaft extension side These head capscrews 17 washers marks can be used for matching in 16 and flange adapter reassembling pump Fig 2 19 Fig 4 5 Using 3 4 wrench loosen and 7 Remove body o ring 6 pressure remove capscrews 14 and washers balance o ring 5 and back up 13 Fis 5 ring 4 Fig 7 6 Remove pump from vise Using wood mallet or plastic hammer tap connector bosses to loosen cover plate 1 Lift plate 8 Remove pressure plate 8 straight up off gear journals Remove o rings 7 from journal Figo 6 bores of pressure plate Fig 8 9 Lift drive gear 10 and idler 11 Dowels 9 are pressed into gear 11 straight up out of gear gear plate There are four dowels plate Fig 8 on each side and unless gear plate is replaced it is not necessary to remove them To remove the dowels use a rod or punch and hammer
11. ace a clean block of wood between the vise jaw and the seal Tighten the vise slowly until the block rests against the flange plate Make sure the seal moves straight into the bore Fig 6 12 13 14 Loosen the vise and place a socket wrench having an o d slightly smaller than the seal bore against the seal Tighten the vise and press the seal in until it clears the groove in the bore Apply two or three drops of 290 loctite at the outer diameter of the seal Rotate the flange in such a manner that the loctite runs around the o d of the seal where it makes contact with the bore Install the snap ring and wipe excess loctite out of the seal bore Also remove any that may have gotten ds on the seal lip Fig 7 Installation of the flange on the pump can now be done Provide for proper protection of the seal lip 3 as outlined in steps 32 and 33 of these instructions Replace the plate o ring pressure balance o ring and the back up strip in the flange plate Slide the flange plate carefully down the shafts until it rests against the gear plate Make sure o rings remain in place Engage the stud threads and run the studs into the plate Install washers and nuts 5 Tighten stud nuts to 70 to 75 1b ft of torque If your pump uses the adapter arrangement flange mount reinstall the adapters capscrews and washers Torque the capscrews to 35 1b ft 15 INSPECTION OF PARTS Visually inspect a
12. and flange mount arrangement reinstall the adaptors cap Screws and washers Torque the capscrews to 35 lb ft 6 13 INSPECTION OF PARTS Visually inspect all parts It is not necessary to set up gauges to check the amount of wear on the punp parts After a visual inspection those parts which are in questionable condition should be replaced with new ones Note the bores in the gear plate On the discharge side you will see a milled groove in the center of the plate During the initial break in at the factory the gears cut into the suction side Nominal depth of this cut is 008 and should not ex ceed 015 Small bits of metal are sometimes pulled out of the surface during break in This is not det rimental If the cut is deeper than 015 or the plate is cracked or damaged in some other way it should be rejected Examine the gears If excessive wear is visible on the journals sides or faces of the gears or at the point where the drive gear shaft rotates in the lip seal reject them If splines or keyways are excessively worn re place the drive gear Examine the pressure plates They should not show excessive wear on the bronze side If deep curved wear markes are visible replace the plate with new ones Shaft seals should be replaced All o ring seals and back up rings or strips should be replaced with new Bearing i d s should have a gray coating If bronze can be seen shining through the teflon o
13. ce seal into place using a flat steel rod slightly smaller in diameter than the O D of the seal This will permit the tool to enter the seal recess and bottom the rotary seal on the stop The front cover 4 must be backed up on a smooth clean surface to prevent damaging its face The load to force seal into place should be applied exactly in line with the housing seal bore to prevent bending the seal steel retainer and or scoring the seal housing bore 3 Install the V seal 6 the gasket 7 and heat shield 8 into the front cover cavity as follows The small vent hole through all of these parts shall be in line and positioned next to the scribe mark on the island previously made during disassembly This position locates the vent holes on the outlet side of the pump The lips on the V seal shall face toward the cavity and be tucked into the groove with the aid of a dull tool to prevent damage to the rubber surface A small screw driver can be used The gasket shall be pressed firmly toward the bottom of the cavity with the thumbs so as to insure all of its perimeters are completely within the groove to avoid interference with subsequent assembly The heat shield shall be firmly pressed toward the bottom of the cavity with the thumbs to provide sufficient space for the wear plate 4 Install o ring 10 into the groove provided in front cover face Oil the o ring and stretch it slightly if necessary so that it will remain
14. cing flange plate 1 FIG 18 25 Because studs are threaded into the flange plate and o ring stabilizers 28 Install nylon back up strip 8 are used in the bearing plate pressure balance o ring 9 and assembly of the pump must begin flange o ring 10 A very thin with the flange plate coat of clean heavy grease may be applied to the o rings to hold them 26 Obtain two pieces of wood 2 by 4 in the grooves Fig 19 about 6 to 10 long Lay them on the workbench parallel to each other and with the 4 dimension vertical to the bench Position the flange plate on the blocks so that it will have steady support and the drive shaft extension will go between the blocks when the drive gear is installed Fig 17 FIG 19 29 If for any reason gear plate 2 has to be replaced dowels 11 must be installed in both sides of the gear plate before assembling it to the flange plate The dowels can be FIG 17 tapped in with a hammer but it is best to use a dowel guide and press 27 Examine flange plate 1 and make Whichever method is used make sure sure shaft seal 6 and snap ring 7 the dowels are started straight in have been properly installed With the bores If the press is used do the o ring groove facing up and the not apply a heavy rapid force to matching mark you made in step 2 the dowels If a hammer is used
15. ctive replace as a cartridge 12 If relief valve is defective replace as complete relief valve unit Inspection Drive 13 or 15 and Driven 12 Gear Assemblies Inspect shafts for roughness in the bearing and sealing areas Measure for wear Minimum acceptable 4998 in D 7492 in H and 9365 in M 5J surface finish maximum Inspect keyway keys or splines for damage or excessive wear Inspect the gear end faces outside diameter and teeth for roughness and Score marks The O D of the D gears must be 1 2395 minimum H gears must be 1 7140 minimum and the M gears 2 1047 minimum For minimum gear widths see Table A Be sure snap rings are secure break any sharp edges on the sides of the gears Gears and shafts are available only as assemblies One gear assembly may be replaced separately if the other is in good condition Table A D SERIES H SERIES M SERIES Minimum Minimum Minimum Size Gear Width Size Gear Width Size Gear Width D05 1875 D07 2770 H25 4531 D09 3463 H31 5663 Mog 1 0756 D11 4309 H39 7079 M11 1 3446 D14 5412 H49 8849 M14 1 6807 D17 6655 H62 1 1072 D22 8597 H77 1 3840 D27 1 0562 H90 1 6740 Front Cover 4 and Back Cover 21 Assemblies If any bearing bore diameter exceeds 5015 in the D Series 7518 in the H Series or 9394 in the M Series the cover should be discarded Bearin
16. d around pressure plate bores Angle groove on face of pressure plate Lube groove enlarged and edges rounded Dull area on shaft at root of tooth Dull finish on shaft in bearing area Sandblasted gear bore in housing Scored pressure plates Scored shafts Scored gear bore Any external damage to pump Damage on rear of drive gear and rear pressure plate only Eroded pump housing Eroded pressure plates Heavy wear on pressure plate Heavy wear on end of gear Housing scored heavily Inlet peened and battered Foreign object caught in gear teeth Pressure plate black O rings and seals brittle Gear and journals black Broken shaft Broken housing or flange GRESEN GRESEN PRODUCTS PARKER HANNIFIN 4675 CLARK RD SARASOTA FL 34233 TEL LA Abrasive wear caused by fine particles 1 Dirt fine contami nants not visible to the eye Abrasive wear caused by metal particles 1 Metal coarse contaminants visible to the eye Incorrect Installation Aeration Cavitation 1 Restricted oil flow to pump inlet 2 Aerated oil Lack of Oil Damage caused by metal object Excessive Heat Vill Over Pressure 941 921 2380 FAX 941 921 8516 Was clean oil used Was filter element change period correct Were correct filter elements used Cylinder rod wiper seals in good condition Cylinder rods dented or scored Was system flushed properly after previous failure Was sy
17. dition Cylinder rods dented or scored Was system flushed properly after previous failure Was system flushed properly after previous failure Contaminants generated else where in hydraulic system Contaminants generated by wearing pump components Did shaft bottom in mating part Any interference between pump and machine Tank oil level correct Oil viscosity as recommended Restriction in pump inlet line Air leak in pump inlet line Loose hose or tube connection near or above oil level in tank Excessive operation of relief valve Was oil level correct Any leaks in piping inside tank Any oil returning above oil level Metal object left in system during initial assembly or previous repair Metal object generated by another failure in system Was a valve stuck Was relief valve too low Was oil viscosity correct Was oil level correct Relief valve setting correct Did relief valve function GRESEN GRESEN HYDRAULICS DIVISION DANA CORPORATION PO BOX 25000 GREENVILLE SC 29616 PHONE 864 234 0444 FAX 864 234 4615 CATALOG NO GSP 185 Rev 10 96 Printed in U S A Pop Finding 1f Biller Way Copyright 1996 Dana Corporation 2 o K Ca CLED GRESEN TP16 series Service Instructions Gresen Products Parker Hannifin Sarasota Facility 4675 Clark Rd Sarasota FL 34233 2 _ SS
18. do facing toward you place the flange not drive the dowels in aggresively on the blocks with the seal Tap them lightly until they bottom centered between them Fig 18 against the shoulder Fig 20 30 31 FIG 20 Turn the gear plate so that the cast recesses in its outer edge faces up and align its matching mark step 2 with the mark on the flange plate Match dowels with bores in the flange plate Tap the gear plate lightly with the plastic hammer until it rests on the o ring in the flange plate Fig 21 FIG 21 Install o rings 12 in the pressure plate 13 With the trap small oblong hole in the pressure plate facing toward the discharge side of the gear plate and the bronze side facing up slide the pressure plate down the gear bores until it rests against the o ring and back up ring Fig 22 33 FIG 22 Check the extension end of the drive gear shaft 14 for burrs and sharp edges If present remove them with medium grit sandpaper After sand paper has been used clean the part thoroughly If the extension end of the drive gear shaft is splined coat the splines with clean heavy grease This will help protect the seal as the shaft slides through it If the shaft has a keyway cover the key way with transparent tape Fig 23 FIG 23 34 Install drive gear 14 in the gear bore nearest to the matching mark Install the idler gear 15 in the opposite bore
19. e to proper viscosity c Air leak in inlet line c Check plumbing d Partly blocked inlet line d Check for foreign object and or clean 2 Foaming Oil a Pump cavitating a See 1a 1b 1c 1d b Water in the oil b Check reservoir and or heat exchange 3 Pump or oil overheating a Oil supply too thin a Drain and fill with proper viscosity oil b Oil supply contaminated b Drain clean filter amp fill with clean oil c Pump cavitating c See 1a 1b 1c 1d d Pump drive shaft excessively misaligned d Check alignment with pump driven shaft e Check for clearance at ends of shafts for e Pump drive shaft axially loaded by shaft misalignment or worn driving keys driving shaft Prime Mover keyways or splines If pulley drive check for f System relief valve bypassing belt alignment f Check relief valve setting see 4c 4 Low Flow a Pump cavitating a See 1a 1b 1c 1d b Foaming oil b See 2a 2b c Relief valve leaks or set too low c Check relief valve for foreign particles d Speed too low d Check prime mover speed e Oil too hot e Check temperature see 3a 3b 3c 3d amp 3e 5 Failure to build pressure a Defective relief valve a Check and reset or replace b Low oil supply b Fill reservoir Darker Hydraulics Parker Hannifin Corporation Hydraulic Pump Motor Division Greeneville Tennessee Series D H M Fixed Displacement Gear Pumps Bulletin 2630 C1 Disassembly Instructions 1 Clean unit thoroughly
20. groove Oil the o ring the cover face and the bearings Install the back cover so that the scribe marks are in line with the marks on the center section and front cover 10 The housing retaining screws shall be alternately tightened to 190 210 in lbs on the D Series 190 210 in Ibs on the H Series and 355 375 in lbs on the M Series Add a generous amount of clean oil into both ports to insure the pump is adequately lubricated Rotate the drive shaft to distribute the oil and check for freedom of shaft rotation Shaft shall be free to rotate with the help of a short wrench 100 in Ibs maximum Testing Procedure After pump has been re installed run for 2 3 minutes before pressurizing Try to apply pressure gradually for an additional five minutes but do not pressurize for longer than 5 seconds at a time Barker Hydraulics Parker Hannifin Corporation Hydraulic Pump Motor Division Greeneville Tennessee N WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH PERSONAL INJURY AND PROPERTY DAMAGE This document and other information from Parker Hannifin Corporation its subsidiaries and authorized distributors provide product and or System options for further investigation by users having technical expertise It is important that you analyze all aspects of your application including consequences of any failure and review the info
21. gs are not supplied separately Replace the shaft seal 3 only if it shows excessive wear or cracking Check all internal threads for damage Bearings must be below the cover faces and show no signs of contact with snap rings on gear shafts If bearings are scored rough or show signs of heat discoloration the cover assemblies should be replaced Center Section 11 Inspect the wall of gear bore diameters for excessive wear of score marks The center section gear bores will show signs of wear on the inlet side of the pump A wear ridge will develop at the end of the gear bore where the thrust plate is located This wear ridge should not exceed 1 32 Lightly tap the faces to remove any nicks or burrs Do not break inside edges Wear Plate 9 and Thrust Plate 16 Inspect bronze wear surfaces for excessive roughness or heat discoloration If wear ridges exceed 0005 discard and replace General The following parts should be replaced at every major overhaul Wear Plate 9 Thrust Plate 16 Fiber Heat Shield 8 Paper Gasket 7 V Seal 6 and O rings 10 and 17 The shaft seal 3 should be replaced only when necessary Reassembly Procedure 1 All parts must be thoroughly cleaned prior to reassembly by dipping in solvent and brushing to remove all traces of contamination Pump should be assembled in a dirt free area 2 Install shaft seal 3 if it was removed in front cover with the spring loaded lip facing inward For
22. he seal facing movable jaw Place clean block of wood against seal and tighten the vise slowly until wood block is against the flange Make sure the seal is started and pressed straight into the bore Fig 6 12 12 Loosen the vise and remove the block of wood Place a socket wrench having an O D just slightly smaller than seal bore against seal Tighten vise against socket and press Seal in until seal has just cleared snap ring groove in seal bore Apply two or three drops of 290 Loctite against seal bore and O D of seal Hold the flange at a 45 degree angle and rotate it slowly to allow the loctite to flow all the way around the OD of the seal If your flange gets snap ring in seal bore install the snap ring and wipe the excess loctite out of seal bore and any that might have gotten on seal lip Fig T 13 Install flange o ring and E shaped back up strip Use clean heavy grease to hold the o rings and back up strip in position Fig 8 Fig 8 14 If extension end of the drive shaft is splined coat the spline with clean grease If is has keyway cover the keyway with transparent tape This will protect the rubber Ji sealing lip as it slides down the shaft If tape is used make sure all of the tape is removed from the shaft 15 After flange plate has been installed screw the cap Screws in and torque them to 70 to 72 lbs t 16 If your pump uses the adaptor 3s
23. ing and the nylon back up strip Also remove the seal snap ring if one is used Protect the internal pieces from contamina tion Fig 2 FIG 2 Place flange in machinist vise Use cardboard between jaws of vise and flange Fig 3 FIG 3 Slide a punch of appropriate size through the bearing and against the seal s metal casing Hold the punch away from the bearing and drive the seal out without damaging the seal bore Move the punch around the seal as it is driven out Do not allow the punch to rest against the seal bore or bearing while driving the seal out Fig 4 FIG 4 Check the seal bore for scratches If scratches are apparent use a four hundred grit sandpaper to clean up the bore Do not use coarse grit sandpaper It will cut heavy grooves in the bore and will allow the seal to leak around its o d Wash the flange in clean solvent and wipe it dry with a clean shop towel or blow dry with shop air 14 10 IL If an arbor press is available use it to press the new seal into the flange bore If the press is not available place the flange in a vise with the seal bore facing the movable jaw Arrange blocks of wood on each side of the protruding ends of the bearings at the side next to the fixed jaw to prevent pressing on the bearings while the seal is being pressed in Fig 5 y FIG 5 Center the seal over the seal bore with the bottom of its metal casing facing out Pl
24. ll parts It is not necessary to set up gauges to check the amount of wear on the pump parts After a visual inspection those parts which are in questionable condition should be replaced with new ones Note the bores in the gear plate On the discharge side you will see a milled groove in the center of the plate During the initial break in at the factory the gears cut into the suction side Nominal depth of this cut is 008 and should not ex ceed 015 Small bits of metal are sometimes pulled out of the surface during break in This is not det rimental If the cut is deeper than 015 or the plate is cracked or damaged in some other way it should be rejected Examine the gears If excessive wear is visible on the journals sides or faces of the gears or at the point where the drive gear shaft rotates in the lip seal reject them If splines or keyways are excessively worn re place the drive gear Examine the pressure plates They should not show excessive wear on the bronze side If deep curved wear markes are visible replace the plate with new ones Shaft seals should be replaced 1 o ring seals and back up rings or strips should be replaced with new Bearing i d s should have a gray coating If bronze can be seen shining through the teflon on the suction side the bearings and plate they are in should be replaced TROUBLESHOOTING GUIDE FOR GEAR TYPE HYDRAULIC PUMPS IDENTIFICATION Sandblasted ban
25. n the suction side the bearings and plate they are in should be replaced TROUBLESHOOTING GUIDE FOR GEAR TYPE HYDRAULIC PUMPS IDENTIFICATION CAUSE CORRECTIVE CHECKS Sandblasted band around pressure plate bores Angle groove on face of pressure plate Lube groove enlarged and edges rounded Dull area on shaft at root of tooth Dull finish on shaft in bearing area Sandblasted gear bore in housing Scored pressure plates Scored shafts Scored gear bore Any external damage to pump Damage on rear of drive gear and rear pressure plate only Eroded gear plate Eroded pressure plates Heavy wear on pressure plate Heavy wear on end of gear Gear plate scored heavily Inlet peened and battered Foreign object caught in gear teeth Pressure plate black O rings and seals brittle Gear and journals black Broken shaft Broken gear plate or flange Abrasive wear caused by fine particles 1 Dirt fine contaminants not visible to the eye Abrasive wear caused by metal particles 1 Metal coarse contami nants visible to the eye Incorrect Installation Aeration Cavitation 1 Restricted oil flow to pump inlet 2 Aerated oil Lack of Oil Damage caused by metal object Excessive Heat Over Pressure Was clean oil used Was filter element change period correct Were correct filter elements used Cylinder rod wiper seals in good con
26. nd vise jaws a plastic hammer E Fig 2 bosses to loosen cover plate 5 Fig 4 FIG 2 E Remove cover plate o ring 10 pressure balance o ring 9 and nylon back up strip 8 Fig 5 FIG 5 10 Reach inside the gear plate and grasp pressure plate 13 Care fully start lifting it out of the gear bores If it hangs as you move it up work it gently back and forth until it will slide out freely 8 Remove pressure plate 13 Remove Remove o ring 12 from the journal o rings 12 from the journal bores bores in the pressure plate Fig 8 of the pressure plate Fig 6 ll Remove gear plate 4 by tapping on its exposed edges while holding 9 Slide idler gear 19 and drive the bearing plate gear 18 straight up and out of After it loosens it can be lifted the gear plate Fig 7 off Fig 9 14 While holding bearing plate 3 tap around the exposed edges of the gear plate After the bearing plate loosens remove it Fig 12 FIG 9 12 Remove bearing plate o ring 10 pressure balance o ring 9 and nylon back up strip 8 Fig 10 15 Remove shaft coupling 17 from the suction port in the bearing plate Remove o ring stud stablizers 16 from dowel bores in the bearing plate Remove beari late o ri 10 pressure balance and nylon back up strip 8 Fig 13
27. remove the plate size through the bearing and o ring E shaped o ring and against the seals metal casing back up strip Also remove Hold the punch away from the the shaft seal snap ring from bearings and drive the seal seal bore Pumps with mount out without damaging seal ing adaptors do not get shaft bore or bearing Move the seal snap ring Fig 2 punch around the seal as it is driven out Do not allow the punch to rest against the seal bore or bearing while driving the seal out Fig 4 Fig 2 6 Place flange plate in machin 8 Check the seal bore for ist vise Use cardboard be scratches If scratches are apparent us a four hundred grit sandpaper to clean up the bore Do not use coarse grit sandpaper It will cut heavy grooves in the bore and will allow the seal to leak around the O D tween jaws of vise and flange plate Fig 3 9 Wash the flange plate in clean solvent and wipe it dry with clean shop towels or blow it dry with shop air 10 11 If an arbor press is avail able use it to press the new seal into flange bore If the press is not available place the flange in a machin ist vise with the seal bore facing the movable jaw Arrange blocks of wood on each side of the protruding ends of the bearings at the Side next to fixed jaw to prevent pressing on the bearings while the seal is being pressed in Fig 5 Fig 3 Center the seal over the seal bore with metal face of t
28. rmation concerning the product or system in the current product catalog Due to the variety of operating conditions and applications for these products or systems the user through its own analysis and testing is solely responsible for making the final selection of the products and systems and assuring that all performance safety and warning requirements of the application are met The products described herein including without limitation product features specifications designs availability and pricing are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice Offer of Sale The items described in this document are hereby offered for sale by Parker Hannifin Corporation its subsidiaries or its authorized distributors This offer and its acceptance are governed by the provisions stated in Catalog 1550 USA on the page entitled Offer of Sale Parker Hannifin Corporation Hydraulic Pump Motor Division 2745 Snapps Ferry Road Greeneville TN 37745 USA j Tel 423 639 8151 Hydraulics Fax 423 787 2418 Web site www parker com pumpmotor Bulletin 2630 C1 1 2000 IGS Printed in USA GSP 185 GRESEN DANA Service Instructions No Longer Required as of 4 1 96 P16 PARTS IDENTIFICATION 6 TEM NAME OF PART Ko NAME OF PART COVER PLATE 2 3 z E GEAR PLATE FLANGE PLATE 8 9 0 SL BACK UP RING O RING PRESSURE BALANCE u 7 ocana P
29. stem flushed properly after previous failure Contaminants generated elsewhere in hydraulic system Contaminants generated by wearing pump com ponents Did shaft bottom in mating part Any interference between pump and machine Tank oil level correct Oil viscosity as recommended Restriction in pump inlet line Air leak in pump inlet line Loose hose or tube connection near or above oil level in tank Excessive operation of relief valve Was oil level correct Any leaks in piping inside tank Any oil returning above oil level Metal object left in system during initial assembly or previous repair Metal object generated by another failure in system Was a valve stuck Was relief valve too low Was oil viscosity correct Was oil level correct Relief valve setting correct Did relief valve function CATALOG NO GSP 200 REV 11 00
30. the shaft Fig 29 FIG 29 check to make sure that the o rings and back up strip have not slipped out of their grooves With the bearing plate contacting the dowels use hand pressure to push it down until the o ring is firmly against the gear plate Fig 30 4l 42 FIG 30 Place a stabilizer o ring 16 in each dowel bore in the bearing plate Install bearing plate o ring 10 pressure balance o ring 9 and nylon back up strip 8 Fig 31 FIG 31 Continue assembly of the pump following steps 29 30 31 34 and 35 Make sure the rear drive gear spline is engaged with the coupling 43 Install cover plate o ring 10 pressure balance o ring 9 and nylon back up strip 8 in cover plate 5 Apply a light coat of clean heavy grease to hold the o rings in their grooves Use hand pressure to push the cover plate down on the dowels until the o ring makes contact with the gear plate Fig 32 FIG 32 44 Coat the stud threads with a light coat of oil Install washers 21 and nuts 22 Torque the nuts to 70 to 75 1b ft using a diagonally opposite sequence of tightening Figure 33 FIG 33 45 Use a 12 adjustable wrench and see if the shaft turns properly It will have resistance but should turn with a maximum torque of 25 1b ft applied Fig 34 12 FIG 34 If your pump has mounting adapter 23 install the adapter If it has a flange adapter also make
31. with solvent kerosene or other non corrosive cleaning fluid which will not affect rubber components 2 Scribe a line across the three sections of the pump to act as a guide in reassembly 3 Remove the six screws 1 Remove the key 14 from the drive shaft Four screws in D series 4 Remove the front cover 4 by lightly tapping the flange with a soft metal hammer 5 The center section 11 will remain attached to either the front cover 4 or back cover 21 Place the drive gear 13 or 15 into the unseparated sections and while holding the center section 11 tap lightly to separate Be careful to avoid cocking on the dowel pins 5 6 Remove wear plate 9 and thrust plate 16 7 Mark the front cover island next to the pressure vent hole in the heat shield 8 gasket 7 and V seal 6 to act as a guide in reassembly The location of this vent hole determines pump rotation 8 Use a small diameter wire a paper clip will do to remove the phenolic heat shield 8 the paper compound gasket 7 and the rubber V seal 6 Discard these parts and replace when pump is reassembled 9 Remove both o rings 10 and 17 and discard They also should be replaced 10 Do not remove shaft seal 3 in the front cover 4 unless it is damaged or leaking If seal is to be replaced use great care not to damage the seal recess or bearing Heating the cover in an oven to 250 F will reduce the press fit 11 If flow control is defe
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