Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic Pumps and Motors {3203, 4351, 5058, 5070} Caterpillar


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Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic Pumps and Motors {3203, 4351, 5058, 5070} [REHS1607]
HYDRAULIC SYSTEM
MOTOR GP
Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic Pumps and Motors {3203, 4351, 5058, 5070}
1.1. Introduction
2.1. Summary
3.1. Important Safety Information
4.1. Canceled Part Numbers and Replaced Part Numbers
5.1. Type Code Breakdown
6.1. Document Coverage
7.1. Fabricated Tooling
8.2. V-Block
9.2. Measuring Plate Group
10.1. Rotating Group Adjustments
11.2. A2FM/A2FE Motors and A2FO Pumps for "Old Style" with a Spanner Nut
12.3. Bearing Preload Adjustment for the A2FM/A2FE/A2FO "Old Style"
13.3. Rotating Group Positioning for the A2FM/A2FE/A2FO "Old Style"
14.3. Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "Old Style"
15.2. A2FM/A2FE Motor and A2FO Pumps - "New Style" With a Snap Ring
16.3. Bearing Preload Adjustment - A2FM/A2FE/A2FO "New Style"
17.3. Rotating Group Positioning - A2FM/A2FE/A2FO "New Style"
18.3. Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "New Style"
19.2. A4VG - Series 32
20.3. Lift-Off Clearance Adjustment - A4VG
21.2. A6VM/A6VE Motor
22.3. Bearing Preload Adjustment - A6VM/A6VE 55/140/160 cc
23.3. Bearing Preload Adjustment - A6VM 200 cc
24.3. Bearing Preload Adjustment - A6VM/A6VE 28/80/107/160/200 cc
25.3. Bearing Preload Adjustment - A6VM/A6VE 250 cc
26.3. Bearing Preload Adjustment - A6VM/A6VE 355 cc
27.3. Lift-Off Clearance Adjustment - A6VM/A6VE 28-200 cc with the Type 1 Barrel
28.3. Lift-Off Clearance Adjustment - A6VM/A6VE 200/250/355 cc with the Type 2 Barrel
29.2. A8VO Pump
30.3. Bearing Preload Adjustment - A8VO 107/160 cc
31.3. Bearing Preload Adjustment - A8VO 200 cc
32.3. Lift-Off Clearance Adjustment - A8VO
33.2. A11VO/A11VLO
34.3. Lift-off Clearance Adjustment - A11VO/A11VLO
35.3. A20VLO
Agricultural Tractor
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Introduction

Table 1
Revision  Summary of Changes in REHS1607 
16  Updated serial number prefixes. 
15  Corrected Table 41 
14  Updated document to include A11VO 95cc values. Added A6VM 160cc bearing preload info. 
13  Updated serial number prefixes. 
12  Updated Off-Highway Truck/Tractor effectivity. 
11  Updated Illustration 22 . 
10  Added new procedure "Bearing Preload Adjustment - A6VM 200 cc". 
09  Added part number 437-5508 Plug for A11 145cc pump to "Lift-Off Clearance Adjustment - A11VO/A11VLO" section of document. 
08  Changed title from "Rotating Group Adjustment Instructions for Bosch Rexroth Pumps and Motors" to "Rotating Group Adjustment Instructions for Bosch Rexroth Hydraulic Pumps and Motors". 
Added "Important Safety Information".
07  Added part number 372-6543 Gauge Plate for A8 107cc pump to "Lift-Off Clearance Adjustment - A8VO" section of document. 
Added part number 372-6544 Gauge Plate for A8 200 cc pump to "Lift-Off Clearance Adjustment - A8VO" section of document.
Added "Important Safety Information" section to document.
06  Made Major changes to "Lift-Off Clearance Adjustment - A6VM/A6VE 200/250/355 cc with the Type 2 Barrel" and "Lift-Off Clearance Adjustment - A8VO" sections. 
Added part number 272-1417 Gauge Plate for A8 160 cc pump to "Lift-Off Clearance Adjustment - A8VO" section of document.
Removed part number 149-4932 Gauge Plate for A8 160 cc pump from "Lift-Off Clearance Adjustment - A8VO" section of document.
Removed part number 149-4931 Gauge Plate for A8 107 cc pump from "Lift-Off Clearance Adjustment - A8VO" section of document.
Removed part number 187-6278 Gauge Plate for A8 200 cc pump from "Lift-Off Clearance Adjustment - A8VO" section of document.

© 2020 AVSpare All Rights Reserved. This guideline is for the use of AVSpare Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables AVSpare dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to AVSpare. 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 AVSpare.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

This special instruction standardizes the instructions for the adjustment of the rotating group for Bosch Rexroth hydraulic piston pumps and motors. This document will be a source to find the instructions for the adjustment of the rotating group for all AVSpare equipment that incorporates Bosch Rexroth hydraulic piston pumps and motors.

Summary

This special instruction standardizes the instructions for the adjustment of the rotating group for Bosch Rexroth hydraulic piston pumps and motors. This document will be a source to find the instructions for the adjustment of the rotating group for all AVSpare equipment that incorporates Bosch Rexroth hydraulic piston pumps and motors.

Important Safety Information



Illustration 1g02139237

Work safely. 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. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by AVSpare is used, you must ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood 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.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.



Illustration 2g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. AVSpare dealers can supply the most current information.

Canceled Part Numbers and Replaced Part Numbers

This document may not include all Canceled part numbers and replaced part numbers. Use NPR on SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Type Code Breakdown

Pumps manufactured by Bosch Rexroth may be labeled several different ways including: Brueninghaus Hydromatik GMBD, Mannesmann Rexroth, Rexroth Corp. the Mobile Hydraulic Division, Rexroth-Sigma, or Uchida Hydraulics Co. LTD. Bosch Rexroth has a group of numbers and letters attached to each pump known as pump identification or a pump description. The typical pump or motor description can be broken down as follows:

Table 2
   
Type Code  A20  60  EP  61 

(1) Axial Piston Unit Family

A - Metric version

AA - SAE version

(2) Displacement Type

V - Variable Displacement

F - Fixed Displacement

(3) L if Long Life Bearings, else no designation

Note: For A11 pumps, L designates with charge pump, else no designation

(4) Device and Style

M - Motor Standard Design

E - Motor Plug-In Design

G - Closed Circuit Pump

O - Open Circuit Pump

(5) Displacement in cubic centimeters

(6) Control Device

(7) Series and Index

(8) Direction of Rotation

R - Clockwise

L - Counterclockwise

W - Alternating

Note: View from the shaft end

(9) Seal Type

V - FPM Fluoro rubber

P - NBR Nitrile rubber

N - NBR, shaft seal in FPM

Document Coverage

Due to the extensive use of Bosch Rexroth pumps and motors in AVSpare Equipment, it would not be feasible to list all of the associated AVSpare part numbers. The identification refers to the family of the motor or pump, the displacement in cubic centimeters, and the series.

Table 3
Document Coverage 
Family, Device, and Style  Displacement in cc  Series and Index 
A2FM  16 to 180  Series 61 
A2FE  45 to 125  Series 61 
A2FO  45  Series 61 
A4VG  40 to 250  Series 32 
A4VG  250  Series 10 
A6VM  55  Series 60 
A6VM  55 to 355  Series 63 
A6VE  28 to 107  Series 63 
A8VO  107 to 200  Series 60 
A11VO  130 to 260  Series 10/11 
A11VLO  130 to 260  Series 10 
A20VLO  190 to 260  Series 10 

Note: The A10 series of pumps requires no adjustment of the rotary group.

Fabricated Tooling

Certain tooling must be fabricated to perform adjustments to the rotating group for all pumps and motors.

V-Block



Illustration 3g01009274
Tooling for the A2FM/A2FE/A2FO/A8VO pump and motor adjustment for the bearing preload.

  1. To fabricate V-Block, cut a 90 degree vee approximately 150 mm (5.9 inch) wide into a block of wood. Call this dimension (A).

Measuring Plate Group



Illustration 4g01009308
FT2739 Measuring Plate Group
Tooling for the 28-160 cc A2FM/A2FE/A2FO pump and motor adjustment for the lift-off clearance.
(1) 6V-4832 Screw
(2) 126-7181 Sliding Plate
(3) 1P-0456 Drive Plate
(4) 6V-3009 Cross Bar

  1. Fabricate the measuring plate by constructing the 6V-3009 Cross Bar per instructions in print.

  2. Refer to Illustration 4 to assemble the plate group components.


Illustration 5g01009306
FT2786 Measuring Plate Group
Tooling for the adjustment for the lift-off clearance for the A2FM/A2FE/A2FO 180-250 cc motors and pumps.
(5) 5P-8715 Forcing Bolt
(6) 5B-0637 Nut
(7) 3H-0465 Puller Plate
(8) 1U-9895 Crossblock
(9) 1P-0456 Drive Plate
(10) FT2786 Measuring Plate Group

  1. Fabricate the measuring plate by constructing the FT2786 Measuring Plate Group per instructions in print.

  2. Refer to Illustration 5 to assemble the plate group components.

Rotating Group Adjustments

A2FM/A2FE Motors and A2FO Pumps for "Old Style" with a Spanner Nut

Old style A2FM/A2FE motors and A2FO pumps require a spanner nut to set the bearing preload and the rotating torques. Cup springs and a shim are used to set the "lift off" clearance between the barrel and the port plate. New style A2FM/A2FE motors and A2FO pumps use a snap ring for the bearing preload and a center spring for the "lift-off" clearance.



Illustration 6g01118952
"Old Style" A2FM/A2FE Motor and A2FO Pump
(1) Spanner nut
(2) Cup springs

Bearing Preload Adjustment for the A2FM/A2FE/A2FO "Old Style"

This section shows the proper way to set the bearing preload. If bearing preload is too high or low, bearing life will be shortened due to heat generation. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 7g01011046
Bearing group of the "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut
(3) Bolt
(4) Upper Bearing
(5) Lower Bearing

  1. Install both bearings (4) and (5) onto the shaft.

  2. Place the spanner nut on the shaft. Tighten the spanner nut by using a spanner nut wrench.

  3. Place a hex head bolt (3) in the shaft end.

  4. Place the shaft group in the fabricated V-Block as shown in Illustration 8


    Illustration 8g01012576

  5. Place 9S-7354 dial type torque wrench on the installed bolt. Hold bearing outer races with a hand to prevent rotation. Turn the shaft assembly. Observe the torque that is required to turn the shaft assembly. Compare this value with the values from Table 4.

  6. Adjust the spanner nut to set the required rotating torque.

  7. Remove the bolt from the shaft end.

Table 4
Bearing Preload 
Piston Diameter in mm (in)  Displacement in cc  Rotating torque in Nm (in-lb) 
11.2 (0.441)  16  0.10-0.18 (0.89-1.59) 
13.3 (0.524)  28  0.22-0.35 (1.95-3.10) 
16 (0.630)  45  0.37-0.55 (3.27-4.87) 
16.8 (.661)  56  0.45-0.70 (3.98-6.20) 
17.8 (0.701)  63  0.45-0.70 (3.98-6.20) 
18.9 (0.744)  80  0.75-1.10 (6.64-9.74) 
20 (0.787)  90  0.75-1.10 (6.64-9.74) 
20.6 (0.811)  107  1.10-1.50 (9.74-13.28) 
22.3 (0.878)  125  1.10-1.50 (9.74-13.28) 
23 (0.906)  131  1.10-1.50 (9.74-13.28) 
23.6 (0.930)  160  1.50-1.90 (13.28-16.82) 
25 (0.984)  180  1.50-1.90 (13.28-16.82) 

Rotating Group Positioning for the A2FM/A2FE/A2FO "Old Style"



Illustration 9g01118959
Bearing group of "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut
(6) Snap ring
(7) Front cover
(8) Shim

  1. Place cover (7) on shaft assembly.

    Note: Measure without the adjustment shim (8)

  2. Measure the distance (A) from the face of the shaft to the top of the cover.

    Note: Do not include the shaft boss in measurements.

  3. Measure the thickness (B) of the snap ring (6).

  4. Use dimension (C) from the Table 5 minus measured dimension (A). Then subtract measured dimension (B) from that figure. The result is the required thickness of the shim (8). Refer to Table 6 for the shim sizes and the associated part number.

    Dimension (C) - dimension (A) - dimension (B) = required shim thickness.

    Note: Multiple shim combinations may be used to achieve the desired dimension (C).

Table 5
Rotating Group Positioning 
Displacement in cc  Dimension (C) in mm (in) 
16  76.6-76.7 (3.016-3.020) 
28  76.8-76.9 (3.024-3.028) 
45  83.2-83.3 (3.276-3.280) 
56  89.6-89.7 (3.528-3.531) 
63  89.6-89.7 (3.528-3.531) 
80  99.4-99.5 (3.913-3.917) 
90  99.4-99.5 (3.913-3.917) 
107  111.2-111.3 (4.378-4.382) 
125  111.2-111.3 (4.378-4.382) 
131  111.2-111.3 (4.378-4.382) 
160  120.7-120.8 (4.752-4.756) 
180  120.7-120.8 (4.752-4.756) 

Table 6
Adjustment Shim (8) 
Displacement in cc  Shim thickness in mm (in)  Part Number 
16  0.1 (0.004)  144-7804 
0.3 (0.012) 144-7805 
28     
45  0.1 (0.004)  180-1376 
0.3 (0.012) 180-1375 
56  0.1 (0.004)  9T-2904 
0.3 (0.012) 9T-2903 
63  0.1 (0.004)  9T-2904 
0.3 (0.012) 9T-2903 
80  0.1 (0.004)  9T-2582 
0.3 (0.012) 9T-2581 
90  0.1 (0.004)  9T-2582 
0.3 (0.012) 9T-2581 
107  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
125  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
131  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
160  0.2 (0.008)  6E-1704 
0.3 (0.012) 6E-1705 
180  0.2 (0.008)  6E-1704 
0.3 (0.012) 6E-1705 

Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "Old Style"

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off" clearance or the allowable separation can be adjusted by adding or removing shims from the spring cup group in the center pin bore. Excessive leakage will occur during high-pressure spikes which may lead to rotary group damage and poor system performance if the allowable separation is too large.



Illustration 10g01139759
The typical lift-off clearance (F) measurement
(2) Cup spring set
(9) Port plate
(10) Housing
(11) Adjustment shim
(12) Barrel
(13) Center pin
(14) Measuring plate group
(15) Piston retaining plate
(16) Drive plates (3)

  1. Insert the center pin (13). Insert the pistons. Attach the piston retaining plate (15) to the shaft group.

  2. The retaining plate (15) bolts need to be tightened to the specified torque value.


    Illustration 11g01009398
    The arrangement of the 6 cup springs for A2FM/A2FE motor


    Illustration 12g01010870
    The arrangement of the 4 cup springs for A2FO pumps.

    Note: For ease of installation, use a punch or wire to hold spring cups in place.

  3. Refer to the Illustrations 11 and 12 to assemble the cup springs.

  4. Install the original adjustment shim (11).

  5. Fit barrel (12) over center pin (13). Insert each piston into the barrel (12).

  6. Hold the rotating group vertically in a vice by the splined shaft.

    Note: Protect the splines of the shaft from damage.

  7. Swivel barrel to the maximum angle.

  8. Heat motor housing (10) to 80 ° C (176 ° F).

  9. Fit the housing over the rotating group.

  10. Allow the housing to cool.

  11. Install the shims (8) that were selected from the Rotating Group Positioning section. Install the front cover (7) and the snap ring (6).

  12. Use a press or an extractor device to tightly pull the rotary group against the snap ring (6).

  13. Install port plate (9) in the housing.

  14. Insert drive plates (16) in the center of the port plate and the barrel's center bore.

  15. Bolt the appropriate tooling (14) to the housing. Tighten until the port plate is flush with the housing face.

    Note: Tooling Selection

    • for A2FM/A2FE/A2FO 28-160 cc displacement, use FT2739 Measuring Plate Group.

    • for A2FM/A2FE/A2FO 180-250 cc displacement use FT2786 Measuring Plate Group.

  16. Tighten the forcing bolt or screw until the drive plates just contact shim (11).

  17. Measure distance (D) from the face of the top of the H-Bar to the top of the forcing bolt or screw and record.

  18. Tighten the forcing bolt or screw until the cup springs (2) compress and the center pin (13) contacts the shim (11).

    Note: Do not use excessive force once resistance is met.

  19. Measure dimension (E). This is the distance from the face of the H-Bar to the top of the forcing bolt or screw after compression.

  20. Dimension (D) minus dimension (E) yields the lift-off clearance (F).

    dimension (D) - dimension (E) = dimension (F).

  21. Take the lift-off clearance (F) minus required lift-off clearance (G) from Table 7 to find the change in thickness of the shim.

    dimension (F) - dimension (G) = change in shim thickness needed.

    Note: Use only one shim for lift-off clearance adjustment.

    Table 7
    Lift-Off Clearance 
    Displacement in cc  lift-off Clearance (G) in mm (in) 
    16-90  0.15-0.25 (0.006-0.010) 
    107-180  0.25-0.40 (0.010-0.016) 

  22. Select the appropriate shim from Table 8.

    Table 8
    Adjustment Shim (11) 
    Displacement in cc  Shim thickness in mm (in)  Part Number 
    16  1.20 (0.0470)  183-4001 
    1.30 (0.0512) 183-4002 
    1.40 (0.0551) 183-4003 
    1.50 (0.0591) 183-4000 
    45  3.50 (0.1378)  180-1279 
    3.60 (0.1417) 180-1278 
    3.70 (0.1457) 180-1277 
    3.80 (0.1496) 180-1274 
    3.90 (0.1535) 180-1275 
    4.00 (0.1575) 180-1276 
    56  7.05 (0.2776)  144-0597 
    7.15 (0.2815) 144-0598 
    7.25 (0.2854) 144-0599 
    7.35 (0.2894) 144-0600 
    63  3.60 (0.1417)  171-6861 
    3.70 (0.1457) 171-6860 
    3.80 (0.1496) 171-6859 
    3.90 (0.1535) 171-6858 
    4.00 (0.1575) 192-8857 
    80  3.50 (0.1378)  141-0247 
    3.60 (0.1417) 141-0248 
    3.70 (0.1457) 141-0249 
    3.80 (0.1496) 141-0250 
    3.90 (0.1535) 141-0251 
    4.00 (0.1575) 141-0252 
    90  3.50 (0.1378)  141-0247 
    3.60 (0.1417) 141-0248 
    3.70 (0.1457) 141-0249 
    3.80 (0.1496) 141-0250 
    3.90 (0.1535) 141-0251 
    4.00 (0.1575) 141-0252 
    107  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    125  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    131  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    160  3.50 (0.1378)  124-9932 
    3.60 (0.1417) 124-9933 
    3.70 (0.1457) 124-9934 
    3.80 (0.1496) 124-9935 
    3.90 (0.1535) 124-9936 
    4.00 (0.1575) 124-9937 
    180  9.95 (0.3917)  6E-1698 
    10.05 (0.3957) 6E-1699 
    10.15 (0.3996) 6E-1702 
    10.25 (0.4035) 6E-1703 

  23. Disassemble the motor to change the shim. Reassemble the motor with the correct shim.

A2FM/A2FE Motor and A2FO Pumps - "New Style" With a Snap Ring

The new style A2FM/A2FE motors and the A2FO pumps use a snap ring and shims to set the bearing preload. A single coil spring and the shim are used to set the lift off clearance between the barrel and the port plate. Old style A2FM/A2FE motors and A2FO pumps use a spanner nut to set bearing preload and a cup spring set to adjust "lift-off" clearance.



Illustration 13g00992929
"New Style" A2FM/A2FE motor and A2FO pump
(1) Snap ring
(2) Center spring

Bearing Preload Adjustment - A2FM/A2FE/A2FO "New Style"

Bearings for the "new style" motors and the "new style" pumps are received as a kit. The kit includes bearings, adjustment shims, and a retaining clip. This kit sets the necessary bearing preload.

Rotating Group Positioning - A2FM/A2FE/A2FO "New Style"



Illustration 14g01150537
(1) Snap ring
(3) Snap ring
(4) Front cover
(5) Adjustment shim
(6) Bearing kit

  1. Install bearing kit (6) and snap ring (1) on the shaft as shown.

  2. Place cover (4) on shaft assembly.

    Note: Make the measurements without the adjustment shim (5) installed.

  3. Measure the distance (A) from the base of the shaft to the top of the cover (4).

  4. Measure the thickness (B) of the snap ring (3).

  5. Take dimension (C) from Table 9 minus measured dimension (A) minus measured dimension (B) to find the required thickness for the adjustment shim. Refer to Table 10 for the adjustment shim thickness and associated part numbers.

    dimension (C) - dimension (A) - dimension (B) = required shim thickness (5).

Table 9
Rotating Group Positioning 
Displacement in cc  Dimension (C) in mm (in) 
16  76.6-76.7 (3.016-3.020) 
28  76.8-76.9 (3.024-3.028) 
45  83.2-83.3 (3.276-3.280) 
56  89.6-89.7 (3.528-3.531) 
63  89.6-89.7 (3.528-3.531) 
80  99.4-99.5 (3.913-3.917) 
90  99.4-99.5 (3.913-3.917) 
107  111.2-111.3 (4.378-4.382) 
125  111.2-111.3 (4.378-4.382) 
131  111.2-111.3 (4.378-4.382) 
160  120.7-120.8 (4.752-4.756) 
180  120.7-120.8 (4.752-4.756) 

Table 10
Adjustment Shim (5) 
Displacement in cc  Shim thickness in mm (in)  Part Number 
16  0.1 (0.004)  144-7804 
0.3 (0.012) 144-7805 
28     
45  0.1 (0.004)  180-1376 
0.3 (0.012) 180-1375 
56  0.1 (0.004)  9T-2904 
0.3 (0.012) 9T-2903 
63  0.1 (0.004)  9T-2904 
0.3 (0.012) 9T-2903 
80  0.1 (0.004)  9T-2582 
0.3 (0.012) 9T-2581 
90  0.1 (0.004)  9T-2582 
0.3 (0.012) 9T-2581 
107  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
125  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
131  0.1 (0.004)  9T-1576 
0.3 (0.012) 9T-1579 
160  0.2 (0.008)  6E-1704 
0.3 (0.012) 6E-1705 
180  0.2 (0.008)  6E-1704 
0.3 (0.012) 6E-1705 

Note: Multiple shim combinations may be used to achieve the desired dimension (C).

Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "New Style"

This adjustment measures allowable separation between the port plate and the barrel. The "lift off" clearance or the allowable separation can be adjusted by adding or removing shims from the spring group in the center pin bore. Excessive leakage will occur at high-pressure spikes if the allowable separation is too large. The excessive leakage may lead to rotary group damage and poor system performance.



Illustration 15g01011150
The typical lift-off clearance (F) measurement
(2) Center spring
(7) Port plate
(8) Housing
(9) Adjustment shim
(10) Barrel
(11) Center pin
(12) Measuring plate group
(13) Piston retaining plate
(14) Drive plates (3)

  1. Insert the center spring (2) and the original adjustment shim (9) into the center bore of the barrel.

  2. Insert the center pin (11) and loosely attach the piston retaining plate (13).

  3. Insert pistons and tighten retaining plate bolts.

  4. Fit barrel (10) over center pin (11). Insert each piston into the barrel.

  5. Hold the rotating group vertically in a vice by the splined shaft.

    Note: Protect the splines of the shaft from damage.

  6. Swivel barrel (10) to maximum angle.

  7. Heat motor housing (8) to 80 ° C (176 ° F).

  8. Fit housing (8) over the rotating group until seated.

  9. Allow the housing to cool.

  10. Install the shims (5) that were selected from the Rotating Group Positioning section Table 10. Install the front cover (4) and the snap ring (3).

  11. Pull the rotary group against the snap ring (3) by using a press or an extractor device.

  12. Install port plate (7) in the housing.

  13. Insert drive plates in the port plate center or the center bore of the barrel.

  14. Bolt the appropriate tooling (11) to the housing. Tighten until the port plate is flush with the housing face.

    Note: Tooling Selection

    • For the A2FM/A2FE/A2FO 28-160 cc displacement, use FT2739 Measuring Plate Group.

    • For A2FM/A2FE/A2FO 180-250 cc displacement use FT2786 Measuring Plate Group.

  15. Tighten the forcing bolt or screw until drive plates (14) just contact the adjustment shim (9).

  16. Measure distance (D) from the top of the H-Bar to the top of the forcing bolt or screw.

  17. Tighten the forcing bolt until center spring (2) compresses and center pin (11) contacts the adjustment shim (9).

    Note: Do not use excessive force once resistance is met.

  18. Measure dimension (E). This is the distance from the top of the H-Bar to the top of the forcing bolt or screw after compression.

  19. Dimension (D) minus dimension (E) yields the lift-off clearance (F).

    dimension (D) - dimension (E) = dimension (F)

  20. Take the lift-off clearance (F) minus the required lift-off clearance (G) from Table 11 to find the change of the thickness of the shim.

    dimension (F) - dimension (G) = the needed change in shim thickness

    Note: Use only one shim for lift-off clearance adjustment.

    Table 11
    Lift-Off Clearance 
    Displacement in cc  Lift-off Clearance (G) in mm (in) 
    16-90  0.15-0.25 (0.006-0.010) 
    107-180  0.25-0.40 (0.010-0.016) 

  21. Select the appropriate shim from Table 12.

    Table 12
    Adjustment Shim (9) 
    Displacement in cc  Shim thickness in mm (in)  Part Number 
    16  1.20 (0.0470)  183-4001 
    1.30 (0.0512) 183-4002 
    1.40 (0.0551) 183-4003 
    1.50 (0.0591) 183-4000 
    45  3.50 (0.1378)  180-1279 
    3.60 (0.1417) 180-1278 
    3.70 (0.1457) 180-1277 
    3.80 (0.1496) 180-1274 
    3.90 (0.1535) 180-1275 
    4.00 (0.1575) 180-1276 
    56  7.05 (0.2776)  144-0597 
    7.15 (0.2815) 144-0598 
    7.25 (0.2854) 144-0599 
    7.35 (0.2894) 144-0600 
    63  3.60 (0.1417)  171-6861 
    3.70 (0.1457) 171-6860 
    3.80 (0.1496) 171-6859 
    3.90 (0.1535) 171-6858 
    4.00 (0.1575) 192-8857 
    80  3.50 (0.1378)  141-0247 
    3.60 (0.1417) 141-0248 
    3.70 (0.1457) 141-0249 
    3.80 (0.1496) 141-0250 
    3.90 (0.1535) 141-0251 
    4.00 (0.1575) 141-0252 
    90  3.50 (0.1378)  141-0247 
    3.60 (0.1417) 141-0248 
    3.70 (0.1457) 141-0249 
    3.80 (0.1496) 141-0250 
    3.90 (0.1535) 141-0251 
    4.00 (0.1575) 141-0252 
    107  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    125  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    131  3.60 (0.1417)  171-3060 
    3.70 (0.1457) 171-3059 
    3.80 (0.1496) 171-3058 
    3.90 (0.1535) 171-3057 
    4.00 (0.1575) 171-3054 
    160  3.50 (0.1378)  124-9932 
    3.60 (0.1417) 124-9933 
    3.70 (0.1457) 124-9934 
    3.80 (0.1496) 124-9935 
    3.90 (0.1535) 124-9936 
    4.00 (0.1575) 124-9937 
    180  9.95 (0.3917)  6E-1698 
    10.05 (0.3957) 6E-1699 
    10.15 (0.3996) 6E-1702 
    10.25 (0.4035) 6E-1703 

  22. Disassemble to remove the shim then reassemble using the correct shim.

A4VG - Series 32

Lift-Off Clearance Adjustment - A4VG

This adjustment measures allowable separation between the port plate and the barrel. The "lift-off" clearance or the allowable separation can be adjusted by adding or removing shims from the center spring under the ball joint. Excessive leakage will occur at high-pressure spikes if the allowable separation is too large. Excessive leakage may lead to rotary group damage and poor system performance.



Illustration 16g01010526
Typical A4VG pump
(1) Piston retaining ring
(2) Ball joint
(3) Adjustment shims
(4) Spring group
(5) Barrel
(6) Port Plate


Illustration 17g01119004
Required tooling
(1) Piston retaining ring
(2) Ball joint
(5) Barrel
(6) Port Plate
(7) Measuring bell
(8) Test ring or pins (3)
(9) Measuring hub
(10) Alignment plug

  1. Select proper tooling from Table 13.

    Table 13
    Piston diameter in mm (in)  Displacement in cc  Hub (9) Part number  Bell (7) Part number  Test ring (8) Part number  Plug (10) Part number  Test Pins 
    15.2 (0.598)  40  135-8293  128-2744  135-8295  135-8291   
    17 (0.669)  56  128-2743  128-2744  128-2745  128-2741   
    18.4 (0.724)  71  135-8294  128-2744  135-8296  135-8292   
    19.9 (0.783)  90  128-2747  128-2744  129-3877  129-3882   
    22.2 (.874)  125  129-3873  129-3876  129-3878  129-3883   
    25.1 (0.988)  180  129-3875  129-3876  129-3879  129-3884   
    31 (1.22)  250  171-1113  129-3876    171-1114  171-1112(1) 
    (1) 3 171-1112 Test Pins are needed.

  2. Place the port plate (6) on the surface plate. The flat side of the port plate (6) must be facing downward.

  3. Place alignment plug (10) on the port plate (6). The chamfer side of the alignment plug (10) must be facing upward.

  4. Place barrel (5) on the port plate and the alignment plug.

  5. Place test ring (8) on barrel in place of springs.

  6. Install ball joint (2) over the test ring on barrel.

  7. Place the piston retaining ring (1) over the ball joint.

  8. Bolt tool (7) and tool (9) together. Refer to Illustration 17to set the tool (7) and the tool (9) on the barrel.

  9. Measure the distance from the surface plate to the top of the measuring bell to find dimension (A).

  10. Dimension (B) is scribed on the top of the measuring bell (7).

  11. Measured dimension (A) minus dimension (B) yields dimension (C).

    dimension (A) - dimension (B) = dimension (C)

    Note: Do not measure the distance from the surface plate to the top of the piston retaining plate in place of dimension (C). The piston retaining plate may not be square with the surface plate, and the measurement will not be accurate.

  12. Required lift-off clearance (D) from Table 14 minus calculated dimension (C) equals the required shim thickness (3).

    dimension (D) - dimension (C) = required shim thickness.

    Table 14
    Lift-Off Clearance 
    Displacement in cc  Dimension (D) in mm (in) 
    40  89.40-89.60 (3.5197-3.5276) 
    56  99.86-100.06 (3.9315-3.9394) 
    71  108.50-108.70 (4.2717-4.2795) 
    90  117.20-117.40 (4.6142-4.6220) 
    125  130.80-131.00 (5.1496-5.1575) 
    180  148.00-148.20 (5.8268-5.8346) 
    250  170.95-171.20 (6.7303-6.7402) 

  13. Select the appropriate shim from Table 15.

    Note: Use only one shim for adjustment of lift-off clearance.

    Table 15
    Adjustment Shim (3) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    40  0.60 (0.0236)  127-4198 
    0.80 (0.0315) 127-4197 
    1.00 (0.0394) 127-4196 
    1.20 (0.0472) 127-4195 
    56  0.60 (0.0236)  117-7248 
    0.80 (0.0315) 117-7247 
    1.00 (0.0394) 117-7246 
    1.20 (0.0472) 117-7245 
    71  0.60 (0.0236)  142-9433 
    0.80 (0.0315) 142-9432 
    1.00 (0.0394) 142-9431 
    1.20 (0.0472) 142-9430 
    90  0.60 (0.0236)  126-1408 
    0.80 (0.0315) 126-1407 
    1.00 (0.0394) 126-1406 
    1.20 (0.0472) 126-1405 
    125  0.60 (0.0236)  6E-4367 
    0.80 (0.0315) 6E-4366 
    1.00 (0.0394) 6E-4365 
    1.20 (0.0472) 6E-4364 
    180  0.60 (0.0236)  6E-4367 
    0.80 (0.0315) 6E-4366 
    1.00 (0.0394) 6E-4365 
    1.20 (0.0472) 6E-4364 
    250  0.50 (0.0197)  164-8169 
    0.75 (0.0295) 164-8170 

  14. Remove the tooling and install the appropriate shim between the barrel and the spring group.

A6VM/A6VE Motor



Illustration 18g01009509
Typical A6VM motor

Bearing Preload Adjustment - A6VM/A6VE 55/140/160 cc

The bearings are received in a kit. The kit includes bearings, adjustment shim, and the retaining clip. This kit sets the necessary bearing preload.

Bearing Preload Adjustment - A6VM 200 cc

This section shows the proper way to set the bearing preload. If bearing preload is too high or low, bearing life will be shortened due to excessive heat generation. Additionally, if bearing preload is too high the rotating torque will be too high resulting in poor system operation.



Illustration 19g03779116
FT-3275 is required for bearing preload adjustment. Dimensions in millimeters.


Illustration 20g03780123
200 cc motor
(1) Snap ring
(2) Reference spacer
(3) Upper bearing
(4) Adjustment shim
(5) Lower bearing

The following steps will show how to preload the bearings onto the shaft.

  1. Install lower bearing (5) onto the shaft.

  2. Place the adjustment shim (4) onto the lower bearing (5).

  3. Install the upper bearing (3) on top of the adjustment shim (4).

    Note: The following steps will use a reference spacer (2) for measurement with a feeler gauge to determine the master spacer (7) of correct thickness to ensure preload. The reference spacer (2) will later be removed after the measurement is made and replaced with the master spacer (7) of correct thickness.

  4. Place the reference spacer (2) on top of the upper bearing (3).

  5. Install the snap ring (1) into the groove of the shaft.


    Illustration 21g03780623
    (6) FT-3725
    (1) Snap ring
    (2) Reference spacer
    (3) Upper bearing

  6. Once the snap ring (1) is in the groove of the shaft, place the FT-3725 (6) onto the reference spacer (2).

    Note: The large windows of the FT-3725 (6) need to be aligned with the widest part of the snap ring tabs.

  7. Apply 1000 N (225 lb) of press force onto FT-3725 (6).

  8. Apply a strap wrench around the upper bearing (3), and rotate manually for a complete revolution.

    Note: Applying 1000 N (225 lb) of force while rotating bearings will insure that bearings have been fully seated into position before measuring.

  9. While maintaining 1000 N (225 lb) of force on the assembly, use a feeler gauge to measure the gap between the top of the reference spacer (2) and the bottom of the snap ring (1).

    1. Measure the gap thickness through all 4 windows of FT-3725 (6).

    2. Take the average of all 4 measurements from Step 9a.

    3. Add 0.01 mm (0.0004 inch) and the reference spacer (2) thickness to value in Step 9b.

    4. Add 0.06 mm (0.0024 inch) and the reference spacer (2) thickness to value in Step 9b.

      Table 16
      Master spacer (7) for Bearing Preload 
      Displacement in cc  Shim Thickness in mm (in)  Part Number 
      200  3.15 (0.1240)  145-8434 
      3.20 (0.1260) 145-8435 
      3.25 (0.1280) 145-8436 
      3.30 (0.1300) 145-8439 
      3.35 (0.1319) 145-8440 
      3.40 (0.1339) 145-8441 
      3.45 (0.1358) 145-8442 
      3.50 (0.1378) 145-8443 

  10. Refer to Table 16 and select a master spacer whose thickness is between the values in Step 9c and Step 9d.

    Note: The master spacer (7) that was selected from the Table 16 will replace reference spacer (2) to ensure proper preload of the assembly.



Illustration 22g03798865
(7) Master Spacer
(3) Upper bearing

The following steps will show you how to assemble the master spacer (7) after loading the bearings.

  1. Remove all tooling along with snap ring (1) and reference spacer (2) from the assembly.

  2. Place master spacer (7) which was determined in Step 10 onto the upper bearing (3).


    Illustration 23g03780154
    Place snap ring (1) just above the groove of the shaft.
    (1) Snap ring
    (8) Oil Hole
    (9) Snap ring tabs

  3. Install the snap ring (1) just above the groove on the shaft as shown in Illustration 23

  4. Place FT-3275 (6) onto the master spacer (7) and apply 1100 N (250 lb) of press force to the assembly.

  5. Apply a strap wrench around the upper bearing (3), and rotate manually for a complete revolution.

  6. While assembly is loaded, install snap ring (1) into the groove of the shaft.

    Note: Increase force by 100 N (25 lb) increments and rotate bearings until snap ring (1) can be assembled into the groove.

    Note: Oil hole (8) of the shaft needs to be aligned with the opening of the snap ring tabs (9).

  7. Once snap ring (1) is seated in the shaft groove, release all of the press force and remove all tooling.

Bearing Preload Adjustment - A6VM/A6VE 28/80/107/160/200 cc

This section shows the proper way to set the bearing preload. If bearing preload is too high or low, bearing life will be shortened due to heat generation. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 24g01009587
28/80/107/200 cc motor
(1) Snap ring
(2) Adjustment shim
(3) Upper bearing
(4) Adjustment shim
(5) Lower bearing

  1. Install the lower bearing (5) on the shaft.

  2. Measure dimension (B) and the thickness of the lower bearing.

  3. Take dimension (A) from the Table 17 minus the measured dimension (B) to find the required thickness of the shim (4).

    dimension (A) - dimension (B) = required shim thickness.

    Table 17
    Bearing Preload 
    Piston Diameter mm (in)  Displacement in cc  Dimension (A) in mm (in) 
    16 (0.6299)  28  34.95-35.05 (1.3760-1.3800) 
    22.8 (0.8976)  80  40.95-41.05 (1.6122-1.6161) 
    25 (0.9842)  107  44.95-45.05 (1.7697-1.7736) 
    28.7 (1.130)  160  50.95-51.05 (2.0059-2.0098) 
    30.8 (1.2126)  200  52.95-53.05 (2.0846-2.0886) 

  4. Use Table 18 to find an appropriate adjustment shim (4).

    Table 18
    Adjustment Shim (4) 
    Displacement in cc  Shim thickness mm (in)  Part number 
    28  5.90 (0.2323)  209-9972 
    80  3.80 (0.1496)  123-5754 
    3.85 (0.1516) 123-5755 
    3.90 (0.1535) 124-6459 
    3.95 (0.1555) 123-5757 
    4.00 (0.1575) 123-5758 
    107  5.80 (0.2283)  124-9865 
    5.85 (0.2303) 124-9866 
    5.90 (0.2323) 124-9867 
    5.95 (0.2343) 124-9868 
    6.00 (0.2362) 124-9869 
    160  Serviced as a complete kit 
    200  4.80 (0.1890)  145-8429 
    4.85 (0.1909) 145-8430 
    4.90 (0.1929) 145-8431 
    4.95 (0.1949) 145-8432 
    5.00 (0.1969) 145-8433 

  5. Install the appropriate adjustment shim (4) and install upper bearing (3) on the shaft.

    Note: Make sure that upper bearing is fully pressed against lower bearing.

  6. Place the snap ring (1) on the shaft.

    Note: For A6VM107, 142-1380 plate must be placed on the shaft before the retaining ring. This is a required shim.

  7. Select an appropriate shim from the Table 19. The adjustment shim (4) should make the distance between the snap ring (1) and the upper bearing (3) less than 0.05 mm (0.0020 in).

    Table 19
    Adjustment Shim (2) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    28  2.15 (0.0846)  209-9964 
    2.20 (0.0866) 209-9965 
    2.25 (0.0886) 209-9966 
    2.30 (0.0906) 209-9967 
    2.35 (0.0925) 209-9968 
    2.40 (0.0945) 209-9969 
    2.45 (0.0965) 209-9970 
    2.50 (0.0984) 209-9971 
    80  2.65 (0.1043)  123-5763 
    2.70 (0.1063) 123-5764 
    2.75 (0.1083) 123-5765 
    2.80 (0.1102) 123-5766 
    2.85 (0.1122) 123-5767 
    2.90 (0.1142) 123-5768 
    2.95 (0.1161) 123-5789 
    3.00 (0.1181) 123-5770 
    107  3.15 (0.1240)  124-9877 
    3.20 (0.1260) 124-9876 
    3.25 (0.1280) 124-9875 
    3.30 (0.1300) 124-9874 
    3.35 (0.1319) 124-9873 
    3.40 (0.1339) 124-9872 
    3.45 (0.1358) 124-9871 
    3.50 (0.1378) 124-9870 
    200  3.15 (0.1240)  145-8434 
    3.20 (0.1260) 145-8435 
    3.25 (0.1280) 145-8436 
    3.30 (0.1300) 145-8439 
    3.35 (0.1319) 145-8440 
    3.40 (0.1339) 145-8441 
    3.45 (0.1358) 145-8442 
    3.50 (0.1378) 145-8443 

  8. Remove the snap ring from the shaft. Install the proper adjustment shim on the shaft. Replace the snap ring on the shaft.

Bearing Preload Adjustment - A6VM/A6VE 250 cc

This section shows the proper way to set the bearing preload. The bearing life will be shortened due to the heat generation if bearing preload is too high or low. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 25g01117795
250 cc Motor
(6) Snap ring
(7) Required shim
(8) Upper bearing
(9) Adjustment shim
(10) Lower bearing

  1. Press lower bearing (10) on the shaft.

  2. Measure dimension (D) by measuring the distance from the shaft base to top of the lower bearing.

  3. Take dimension (C) from Table 20 minus the measured dimension (D) to find the required adjustment shim thickness.

    dimension (C) - dimension (D) = required shim thickness.

    Table 20
    Bearing Preload 
    Piston Diameter mm (in)  Displacement in cc  Dimension (C) in mm (in) 
    32 (1.2598)  250  86.0-87.0 (3.3858-3.4252) 

  4. Use Table 21 to find an appropriate shim (9).

    Table 21
    Adjustment Shim (9) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    250  7.35 (0.2894)  9T-9453 - kit 
    7.40 (0.2913) 9T-9453 - kit 
    7.45 (0.2933) 9T-9453 - kit 
    7.50 (0.2953) 9T-9453 - kit 
    7.80 (0.3071)(1) 9T-9453 - kit 
    (1) Can be ground to size if required.

  5. Install appropriate shim (9) and press upper bearing (8) on shaft.

  6. Install required shim (7) on shaft and install snap ring (6).

Bearing Preload Adjustment - A6VM/A6VE 355 cc

This section shows the proper way to set the bearing preload. If bearing preload is too high or low, bearing life will be shortened due to heat generation. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 26g01117802
355 cc Motor
(11) Snap ring
(12) Front cover
(13) Upper bearing
(14) Adjustment shim
(15) Lower bearing

  1. Install bearing (15) and shim (14) onto the shaft.

  2. Place front cover (12) on the shaft.

  3. Measure dimension (G). This is the distance from shaft base to the snap ring area of the front cover.

  4. Measure thickness (F) of snap ring (11).

  5. Take dimension (E) from Table 22 minus measured dimension (F) minus measured dimension (G) to find the required change in the thickness of the adjustment shim (14).

    dimension (E) - dimension (F) = required change in shim thickness

    Table 22
    Bearing Preload 
    Piston Diameter mm (in)  Displacement in cc  Dimension (E) in mm (in) 
    36 (1.4173)  355  147.95-148.05 (5.8248-5.8287) 

  6. Select appropriate adjustment shim (14) from Table 23.

    Table 23
    Adjustment Shim (14) 
    Displacement in cc  Shim thickness mm (in)  Part number 
    355  7.30 (0.2874)  191-0678 - kit 
    7.35 (0.2894) 191-0678 - kit 
    7.40 (0.2913) 191-0678 - kit 
    7.45 (0.2933) 191-0678 - kit 
    7.90 (0.3110)(1) 191-0678 - kit 
    (1) Can be ground to size if required.

  7. Remove the front cover and the upper bearing. Insert the appropriate shim and reassemble using the upper bearing (13).

Lift-Off Clearance Adjustment - A6VM/A6VE 28-200 cc with the Type 1 Barrel

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off" clearance or the allowable separation can be adjusted by adding or removing shims from the spring group in the center pin bore. Excessive leakage will occur at high-pressure spikes which may lead to rotary group damage and poor system performance if the allowable separation is too large.



Illustration 27g01009853
Typical lift-off clearance (H) measurement of A6VM/A6VE with type 1 Barrel
(17) Housing
(18) Piston retaining plate
(19) Center pin
(20) Type 1 Barrel
(21) Port plate
(22) Head group


Illustration 28g01119047
Type 1 Barrel
(16) Adjustment shim

Lift-off clearance for a Type 1 barrel is adjusted via a shim (16). The shim (16) is placed in the center bore of the barrel.

Required Equipment

149-4935 Pump and Motor Measuring Group

  1. Insert the complete drive shaft and the bearing assembly with the center pin (19) and the piston retaining plate (18) into the housing (17).

  2. Tightly pull the rotary group against the case cover using a press or an extractor device.

  3. Select the correct gauge plate from the Table 24 to use from kit 149-4935 Pump and Motor Measuring Group.

    Table 24
    Gauge Plates in 149-4935 Pump and Motor Measuring Group 
    Piston Diameter mm (in)  Displacement in cc  Part number  Gauge Plate Thickness mm (in) 
    20
    (0.7874) 
    55  149-4928  9.10
    (0.3583) 
    22.8
    (0.8976) 
    80  149-4930  3.80
    (0.1496) 
    25
    (0.9843) 
    107  149-4931  3.50
    (0.1378) 
    28.7
    (1.1300) 
    160  149-4932  4.50
    (0.1772) 
    30.8
    (1.2126) 
    200  149-4934  4.00
    (0.1575) 

  4. Place three 149-5141 gauge balls in the top of the gauge plate.

    Note: "TOP" is engraved on the gauge plate.

  5. Press the balls gently in the gauge plate.

    Note: Do not press the balls completely in the gauge plate. Hold the balls in place by pressing firmly on the balls. Only apply enough pressure to hold the balls in place.

    Note: The lead balls vary in size. The lead balls must protrude from the gauge plate at least 2.10 mm (0.0827 inch) prior to Step 6 to ensure proper compression of the lead balls.

  6. Place a small amount of grease on the top side of the gauge plate.

  7. Place the "TOP" side of the gauge plate and the balls into the center pin bore of the barrel (20). The grease should hold the gauge plate in place inside the barrel.

  8. Install the cylinder barrel on the center pin.

    Note: Do not drop the barrel onto the center pin. This will lead to premature crushing of the lead balls.

  9. Install the port plate (21) and the head group.

  10. Tighten all of the head bolts to the specified torque while the pump shaft is turning.

    Note: The pump shaft must be rotated while tightening bolts to seat all components.

  11. Loosen and remove the head group and the port plate.

  12. Remove barrel from center pin.

  13. Carefully remove the gauge plate and the flattened balls from the barrel.

  14. Measure the thickness of the gauge plate and flattened balls at each gauge ball location. These are dimensions (X1), (X2), and (X3).

    Note: Repeat the procedure if the measurements at each of the three gauge ball locations are not within 0.05 mm (0.002 in).



    Illustration 29g01011324
    Gauge plate after removal from barrel. The lead shot compressed at each of the three ball locations.

  15. Take the average value of (X1), (X2), and (X3). Call this dimension (X).

    (dimension (X1) + dimension (X2) + dimension (X3)) / 3 = dimension (X).

  16. Take dimension (X) minus the required lift-off clearance (Z) from Table 25 to find the required thickness of the shim.

    dimension (X) - dimension (Z) = required shim thickness.

    Table 25
    Lift-Off Clearance 
    Displacement in cc  Lift-off Clearance (Z) in mm (in) 
    28  0.150-0.300 (0.006-0.012) 
    55  0.150-0.250 (0.006-0.010) 
    80  0.150-0.250 (0.006-0.010) 
    107  0.150-0.250 (0.006-0.010) 
    140  0.200-0.400 (0.008-0.016) 
    160  0.200-0.300 (0.008-0.012) 
    200  0.100-0.300 (0.004-0.012) 

  17. Select the appropriate adjustment shim (16) from Table 26.

    Table 26
    Adjustment Shim (16) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    28  3.50 (0.138)  180-1279 
    3.60 (0.1427) 180-1278 
    3.70 (0.146) 180-1277 
    3.80 (0.150) 180-1274 
    3.90 (0.154) 180-1275 
    4.00 (0.158) 180-1276 
    55  3.50 (0.138)  137-4586 (kit) 
    3.60 (0.141) 137-4586 (kit) 
    3.70 (0.146) 137-4586 (kit) 
    3.80 (0.150) 137-4586 (kit) 
    3.90 (0.154) 137-4586 (kit) 
    4.00 (0.158) 137-4586 (kit) 
    80  3.50 (0.138)  123-5773 
    3.60 (0.142) 123-5774 
    3.70 (0.146) 123-5775 
    3.80 (0.150) 123-5776 
    3.90 (0.154) 123-5777 
    4.00 (0.158) 123-5778 
    107  3.50 (0.138)  124-9932 
    3.60 (0.142) 124-9933 
    3.70 (0.146) 124-9934 
    3.80 (0.150) 124-9935 
    3.90 (0.154) 124-9936 
    4.00 (0.158) 124-9937 
    140  4.50 (0.177)  124-9855 
    4.60 (0.181) 124-9856 
    4.70 (0.185) 124-9857 
    4.80 (0.189) 124-9858 
    4.90 (0.193) 124-9859 
    5.00 (0.197) 124-9860 
    160  4.50 (0.177)  124-9855 
    4.60 (0.181) 124-9856 
    4.70 (0.185) 124-9857 
    4.80 (0.189) 124-9858 
    4.90 (0.193) 124-9859 
    5.00 (0.197) 124-9860 
    200  5.50 (0.217)  145-8452 
    5.60 (0.221) 145-8453 
    5.70 (0.224) 145-8454 
    5.80 (0.228) 145-8455 
    5.90 (0.232) 145-8456 
    6.00 (0.236) 145-8457 

  18. Reassemble the motor with the appropriate shims.

Lift-Off Clearance Adjustment - A6VM/A6VE 200/250/355 cc with the Type 2 Barrel

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off" clearance or the allowable separation can be adjusted by placing shims of different thicknesses under the screw in the Type 2 barrel. The shim sets the depth that the screw can protrude into the center pin bore of the barrel. Excessive leakage will occur at high-pressure spikes which may lead to rotary group damage and poor system performance if separation is too large.



Illustration 30g01010506
Typical lift-off clearance (J) measurement of A6VM/A6VE with type 2 barrel
(23) Center pin
(24) Center pin disk
(25) Adjustment shim
(26) Screw
(27) Piston retaining plate
(28) Type 2 barrel
(29) Port plate


Illustration 31g01119054
Type 2 barrel
(23) Center pin
(24) Center pin disk
(25) Adjustment shim
(26) Screw

Lift-off clearance for Type 2 barrel is adjusted via shim (25) that sets the depth screw (26) can protrude into the center pin bore of the barrel.

Required Equipment

149-4935 Pump and Motor Measuring Group

  1. Insert the complete drive shaft and the bearing assembly with the center pin (23) and piston retaining plate (27) into the housing.

  2. Install the front cover, the shim, and the snap ring.

    Note: Only for the 355 cc displacement pumps and motors.

  3. Tightly pull the rotary group against the case cover using a press or an extractor device.

  4. Tighten the barrel screw (26) with the largest shim (25) from Table 30.

  5. Select the appropriate gauge group from 149-4935 Pump and Motor Measuring Group.

    Table 27
    Gauge groups in 149-4935 Pump and Motor Measuring Group 
    Piston Diameter mm (in)  Displacement in cc  Part number 
    30.8 (1.2125)  200  149-4934 
    32 (1.2598)  250  149-4934 
    36 (1.4173)  355  149-4934 


    Illustration 32g01150541
    (30) Spring pin
    (31) Disc springs
    (32) Gauge disc

  6. Refer to Illustration 32 to set the gauge disc (32) so that the gauge disc (32) is centered on the middle of the spring pin (30).

  7. Place a small amount of grease between the disc springs (31) and the gauge disc (32). Place a small amount of grease on the side of the disc spring (31) to be inserted into the barrel.

    Note: Leave the center pin disc (24) out during the measurement procedure.

  8. Place the gauge assembly in the center pin bore of the cylinder barrel so that the disc springs are facing toward the barrel screw. The grease should hold the gauge plate in place.

  9. Install the cylinder barrel (28) on the center pin (23).

    Note: The resulting measurement will be incorrect if the barrel is dropped onto the center pin.

  10. Install the port plate (29) and the head group.

  11. Tighten all of the bolts to the specified torque while the pump shaft is turning.

    Note: Tighten all of the bolts while the pump shaft is rotating to seat all of the components.

  12. Loosen and remove the head group and the port plate (29).

  13. Remove barrel from center pin (23).

  14. Carefully remove the gauge group from the barrel cylinder.

  15. Remove the disc springs (31) from the gauge group.


    Illustration 33g01010474

  16. Measure the thickness of the gauge group (K) from the top of the spring side of the spring pin (30) to the bottom of the gauge disc (32) as in Illustration 33.

  17. Use Table 28 to assist in calculating the required shim thickness.

    Table 28
    Explanation of Dimensions 
    Dimension  Description 
    Measurement from Illustration 33 
    Lift-off clearance 
    Ideal center pin disc thickness 
    Center pin disc thickness 
    Difference between ideal center pin disc thickness (M) and center pin disc thickness (C) 
    Shim thickness used during measuring procedure(1) 
    Required shim thickness for proper lift-off adjustment 
    (1) This is shim (25) from Illustration 31

    Use the formulas below to calculate the required shim thickness.

    K - L = M

    M - C = X

    S - X = Z

    Note: If (M) is less than (C), you will need to add shim thickness compared to shim (25) used during testing . If (M) is greater than (C), you will need to reduce shim thickness compared to shim (25) used during testing.

    Note: Be sure the difference between the shim thickness you want (Z) and the shim thickness you have to choose from Table 30 are within the tolerance given in Table 29.

    Note: Use only one shim for the adjustment of the lift-off clearance.

    Table 29
    Lift-Off Clearance 
    Displacement in cc  Dimension (L) in mm (in) 
    200  0.25 ± 0.05 (0.0098 ± 0.0020) 
    250  0.20 ± 0.10 (0.0079 ± 0.0039) 
    355  0.25 ± 0.10 (0.0098 ± 0.0039) 

  18. Select appropriate shim (25) from Table 30.

    Table 30
    Adjustment Shim (25) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    200  5.50 (0.2165)  145-8452 
    5.60 (0.2205) 145-8453 
    5.70 (0.2244) 145-8454 
    5.80 (0.2283) 145-8455 
    5.90 (0.2323) 145-8456 
    6.00 (0.2362) 145-8457 
    250  1.70 (0.0669)  9T-9450 (kit) 
    1.75 (0.0689) 9T-9450 (kit) 
    1.80 (0.0709) 9T-9450 (kit) 
    1.85 (0.0728) 9T-9450 (kit) 
    1.90 (0.0748) 9T-9450 (kit) 
    1.95 (0.0768) 9T-9450 (kit) 
    2.00 (0.0787) 9T-9450 (kit) 
    2.05 (0.0807) 9T-9450 (kit) 
    2.10 (0.0827) 9T-9450 (kit) 
    2.15 (0.0846) 9T-9450 (kit) 
    2.20 (0.0866) 9T-9450 (kit) 
    2.25 (0.0886) 9T-9450 (kit) 
    2.30 (0.0906) 9T-9450 (kit) 
    2.35 (0.0925) 9T-9450 (kit) 
    2.40 (0.0945) 9T-9450 (kit) 
    2.90 (0.1142) 9T-9450 (kit) 
    355  1.70 (0.0669)  191-0666 (kit) 
    1.75 (0.0689) 191-0666 (kit) 
    1.80 (0.0709) 191-0666 (kit) 
    1.85 (0.0728) 191-0666 (kit) 
    1.90 (0.0748) 191-0666 (kit) 
    1.95 (0.0768) 191-0666 (kit) 
    2.00 (0.0787) 191-0666 (kit) 
    2.05 (0.0807) 191-0666 (kit) 
    2.10 (0.0827) 191-0666 (kit) 
    2.15 (0.0846) 191-0666 (kit) 
    2.20 (0.0866) 191-0666 (kit) 
    2.25 (0.0886) 191-0666 (kit) 
    2.30 (0.0906) 191-0666 (kit) 
    2.35 (0.0925) 191-0666 (kit) 
    2.40 (0.0945) 191-0666 (kit) 
    2.90 (0.1142) 191-0666 (kit) 

  19. Disassemble the barrel. Replace the shim. Reassemble the barrel.

A8VO Pump



Illustration 34g01010090
Typical A8VO motor rotating group

Bearing Preload Adjustment - A8VO 107/160 cc

This section shows the proper way to set the bearing preload. Bearing life will be shortened due to heat generation if bearing preload is too high or too low. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 35g01150546
(1) Locknut
(2) Adjustment shim
(3) Middle bearing
(4) Lower bearing

  1. Place both bearings on the surface plate.

  2. Measure dimension (B) by measuring the distance from the surface plate to the top of the middle bearing.

  3. Take dimension (A) from Table 31 minus measured dimension (B) to find the required thickness of the shim (8).

    dimension (A) - dimension (B) = required shim thickness.

    Table 31
    Bearing Preload 
    Piston Diameter mm (in)  Displacement in cc  Dimension (A) in mm (in) 
    25 (0.9842)  107  75.95-76.00 (2.9902-2.9921) 
    28.7 (1.1300)  160  86.45-86.50 (3.4035-3.4055) 

  4. Select the appropriate shim from Table 32.

    Table 32
    Adjustment Shim (2) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    107  2.70 (0.1063)  9T-3376 
    2.80 (0.1102) 9T-3377 
    2.90 (0.1142) 9T-3378 
    3.00 (0.1181) 9T-3379 
    3.10 (0.1220) 9T-3380 
    160  6.2 (0.2441)  5I-4480 
    6.3 (0.2480) 5I-4481 
    6.4 (0.2520) 5I-4482 
    6.5 (0.2559) 5I-4483 
    6.6 (0.2598) 5I-4484 

  5. Press lower bearing (4) and middle bearing (3) on the shaft.

  6. Install the adjustment shim (2).

  7. Press the upper bearing on the shaft.

  8. Tighten the locknut (1) on the shaft.

  9. Place a hex head bolt in the shaft end.

  10. Refer to Illustration 36 to place the shaft group in the fabricated V-Block


    Illustration 36g01012323

  11. Place a breaker bar on the installed bolt and hold the bearing's outer races with a hand. Ensure that the shaft rotates with a slight to moderate force.

  12. Remove the bolt before assembling the pump.

Bearing Preload Adjustment - A8VO 200 cc

This section shows the proper way to set the bearing preload. Bearing life will be shortened due to heat generation if bearing preload is too high or low. Additionally, if bearing preload is too high the rotating torque will be too high causing poor system operation.



Illustration 37g01010155
(5) Snap ring
(6) Adjustment shim
(7) Upper bearing
(8) Adjustment shim
(9) Middle bearing
(10) Lower bearing

  1. Place middle bearing (9) and lower bearing (10) on the surface plate.

  2. Measure dimension (F) by measuring the distance from the surface plate to the top of the middle bearing.

  3. Dimension (E) from Table 33 minus measured dimension (F) yields the required shim thickness.

    dimension (E) - dimension (F) = required shim thickness.

    Table 33
    Bearing Preload 
    Piston Diameter mm (in)  Displacement in cc  Dimension (E) in mm (in) 
    30.8 (1.2125)  200  86.4-86.5 (3.4016-3.4055) 

  4. Select appropriate adjustment shim (8) from Table 34.

    Table 34
    Adjustment Shim (8) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    200  6.20 (0.2441)  177-2513 
    6.30 (0.2480) 177-2514 
    6.40 (0.2520) 177-2515 
    6.50 (0.2559) 177-2516 
    6.60 (0.2598) 177-2517 

  5. Press lower bearing (10) and middle bearing (9) on the shaft.

  6. Install the previously selected adjustment shim (8).

  7. Press upper bearing (7) on the shaft.

  8. Measure the thickness of the snap ring (5). This is dimension (D).

  9. Install the snap ring (5) on the shaft.

  10. Measure the distance between the top of the upper bearing and the top of the snap ring. This is dimension (C).

  11. Take measured dimension (C) minus measured dimension (D). The result is the thickness that is required for the shim.

    dimension (C) - dimension (D) = required shim thickness.

    Note: Dimension (C) must be 4.64-4.97 mm (0.1827-0.1957 in).

  12. Select appropriate shim (6) from Table 35.

    Table 35
    Adjustment Shim (6) 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    200  2.60 (0.1024)  177-2491 
    2.65 (0.1043) 177-2492 
    2.70 (0.1063) 177-2493 
    2.75 (0.1083) 177-2494 
    2.80 (0.1102) 177-2495 
    2.85 (0.1122) 177-2496 
    2.90 (0.1142) 177-2497 
    2.95 (0.1161) 177-2498 

  13. Remove the snap ring.

  14. Install the required shim and replace the snap ring.

Lift-Off Clearance Adjustment - A8VO

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off" clearance, or the allowable separation can be adjusted. The "lift-off" clearance or the allowable separation is adjusted by adding or removing shims from the spring group in the center pin bore. Excessive leakage will occur at high-pressure spikes which may lead to damage to the rotary group and poor system performance if the allowable separation is too large.

Note: Perform calibration for each rotary group.



Illustration 38g01010213
Typical lift-off clearance measurement
(11) Piston retaining plate
(12) Center pin
(13) Barrel
(14) Port plate
(15) Adjustment shim

Required Equipment

149-4935 Pump and Motor Measuring Group

372-6543 Gauge Plate

272-1417 Gauge Plate

372-6544 Gauge Plate

  1. Insert the complete bearing assembly into the case with the center pin (12) and the piston retaining plate (11) attached.

  2. Properly seat the rotary group into the case bearing bore by using the press or the extractor device.

  3. Select the correct gauge plate from Table 36 to use from the kit 149-4935 Pump and Motor Measuring Group.

    Table 36
    Gauge Plates 
    Piston Diameter mm (in)  Displacement in cc  Gauge plate part number  Gauge Plate Thickness mm (in) 
    25
    (0.9842) 
    107  372-6543  9.10
    (0.3583) 
    28.7
    (1.1300) 
    160  272-1417  9.62
    (0.3787) 
    30.8
    (1.2125) 
    200  372-6544  12.20
    (0.4803) 

  4. Place three 149-5141 gauge balls in the top of the gauge plate.

    Note: "TOP" is engraved on the gauge plate.

  5. Press the balls gently in the gauge plate.

    Note: Do not press the balls completely in the gauge plate. Only press firm enough to hold the balls in position.

    Note: The lead balls vary in size. The lead balls must protrude from the gauge plate at least 2.10 mm (0.0827 inch) prior to Step 6 to ensure proper compression of the lead balls.

  6. Place a small amount of grease on the top side of the gauge plate to help retain the balls.

  7. Place the gauge plate and the balls with the "TOP" side first into the barrel. The grease should hold the gauge plate in place.

  8. Install the cylinder barrel (13) on the center pin.

    Note: Do not drop the barrel onto the center pin. This will lead to premature crushing of the lead balls.

  9. Install the port plate (14) and the head group.

  10. Tighten all head bolts to the specified torque while the pump shaft is turning.

    Note: The pump shaft must be rotated while tightening bolts to seat all components.

  11. Loosen and remove the head group and the port plate.

  12. Remove barrel from center pin.

  13. Carefully remove the gauge plate from the barrel.

  14. Measure the thickness of the gauge plate and the flattened balls at each gauge ball location. These dimensions are (X1), (X2), and (X3).

    Note: Repeat the procedure if the measurements of each of the three gauge ball locations are not within 0.05 mm (0.002 in).



    Illustration 39g01011324
    The gauge plate after removal from the barrel. The lead shot is compressed at each of the locations of the three balls.

  15. Take the average value of (X1), (X2), and (X3). Call this dimension (X).

    (dimension (X1) + dimension (X2) + dimension (X3)) / 3 = dimension (X).

  16. Take calculated dimension (X) minus the required lift-off clearance (Z) from Table 37 to find the required thickness of the shim.

    dimension (X) - dimension (Z) = required shim thickness.

    Table 37
    Lift-Off Clearance 
    Displacement in cc  Lift-off Dimension (Z) in mm (in) 
    107  0.300-0.500 (0.012-0.020) 
    160  0.300-0.500 (0.012-0.020) 
    200  0.300-0.500 (0.012-0.020) 


    Illustration 40g01119059
    (J) The shim thickness for A8VO 107/160/200

  17. Select appropriate shim (15) in Table 38.

    Note: Use only one shim for adjustment of lift-off clearance.

    Table 38
    Adjustment Shim 
    Displacement in cc  Shim thickness in mm (in)  Part number 
    107  9.55 mm (0.3760 inch)  9T-3391 
    9.65 mm (0.3799 inch) 9T-3392 
    9.75 mm (0.3839 inch) 9T-3393 
    9.85 mm (0.3878 inch) 9T-3394 
    9.95 mm (0.3917 inch) 9T-3395 
    10.05 mm (0.3957 inch) 9T-3396 
    10.15 mm (0.3996 inch) 9T-3397 
    160  9.75 mm (0.3839 inch)  5I-8405 
    9.85 mm (0.3878 inch) 5I-8406 
    9.95 mm (0.3917 inch) 5I-8407 
    10.05 mm (0.3957 inch) 5I-8408 
    10.15 mm (0.3996 inch) 5I-8409 
    10.25 mm (0.40354 inch) 5I-8410 
    10.35 mm (0.4075 inch) 5I-8411 
    10.45 mm (0.4114 inch) 5I-8412 
    10.55 mm (0.4154 inch) 8I-8413 
    200  12.30 mm (0.4843 inch)  177-2509 
    12.40 mm (0.4882 inch) 177-2508 
    12.50 mm (0.4921 inch) 177-2507(1) 
    12.60 mm (0.4961 inch) 177-2506 
    12.70 mm (0.5000 inch) 177-2505 
    12.80 mm (0.5039 inch) 177-2504(1) 
    12.90 mm (0.5079 inch) -(1) 
    13.00 mm (0.5118 inch) -(1) 
    13.10 mm (0.5158 inch) -(1) 
    13.20 mm (0.5197 inch) -(1) 
    13.30 mm (0.5236 inch) -(1) 
    13.40 mm (0.5276 inch) -(1) 
    (1) Included in 247-8851 Spacer Kit

  18. Reassemble the pump with the appropriate adjustment shim.

A11VO/A11VLO

Lift-off Clearance Adjustment - A11VO/A11VLO

This adjustment measures the allowable separation between the port plate and the barrel. The "lift-off" clearance or the allowable separation can be adjusted by adding or removing shims from the center spring under the ball joint. Excessive leakage will occur at high-pressure spikes which may lead to rotary group damage and poor system performance if the allowable separation is too large.



Illustration 41g01010520
Typical A11VO pump
(1) Piston retaining ring
(2) Ball joint
(3) Adjustment shim
(4) Spring group
(5) Barrel
(6) Port Plate


Illustration 42g01119061
Required tooling
(1) Piston retaining plate
(2) Ball joint
(5) Barrel
(6) Port Plate
(7) Measuring bell
(8) Test ring or pins (3)
( 9) Measuring hub
(10) Alignment plug

  1. Select proper tooling from Table 39.

    Table 39
    Piston diameter in mm (in)  Disp. in cc  Hub (9) Pt. No.  Bell (7) Pt. No.  Test ring (8) Pt. No.  Test pins (8) Pt. No.  Plug (10) Pt. No.  Additional Shim 
    22.2 (0.874)  95  129-3874  128-2744  464–4892  464–4893 
    24.8 (0.976)  130  129-3874  128-2744  128-2746  128-2742  6E-0721 
    26.1 (1.03)  145  129-3874  1238-2744  128-2746  437-5508  6E-0721 
    28 (1.106)  190  137-1326  129-3876  137-1329(1)  137-1331 
    29.55 (1.163)  200  129-3875  129-3876  129-3880  129-3903 
    31.8 (1.252)  250  130-9890  129-3876  129-3881  129-3904 
    31.2 (1.220)  260  171-1113  129-3876  171-1112(1)  171-1114 
    (1) Three 137-1329 Test Pins are needed.

  2. Place the port plate (6) on the surface plate. The flat side of the port plate (6) must be facing downward.

  3. Install the alignment plug (10) into the port plate center bore. The chamfer side of alignment plug (10) must be facing upward.

  4. Place the barrel (5) on the port plate and the alignment plug.

  5. Place the test ring (8) or test pins (8) on the barrel in place of springs.

    Note: The 190cc and 260cc pumps require the use of three test pins in place of the test ring. Place the three test pins around the outside diameter of the center pin bore of the barrel. The three test pins must be equally spaced around the center pin bore of the barrel.

  6. Install the ball joint (2) over the test ring pins on the barrel.

  7. Place the piston retaining plate (1) over the ball joint.

  8. Bolt tool (7) and tool (9) together. Place the tool (7) and the tool (9) on the barrel. Refer to Illustration 42.

  9. Measure dimension (A) by measuring the distance from the surface plate to the top of the measuring bell.

  10. Dimension (B) is scribed on the tool (7).

  11. Measured dimension (A) minus dimension (B) yields dimension (C).

    dimension (A) - dimension (B) = dimension (C)

    Note: Do not measure the distance from the surface plate to the top of the piston retaining plate in place of dimension (C). The piston retaining plate may not be square with the surface plate, and the measurement will not be accurate.

  12. Take the required lift-off clearance (D) from Table 40 minus the calculated dimension (C) to find the required thickness of the shim (3).

    dimension (D) - dimension (C) = required shim thickness.

    Table 40
    Lift-Off Clearance 
    Displacement in cc  Dimension (D) in mm (in) 
    95  122.45-122.65 (4.8208-4.8287) 
    130  136.75-136.95 (5.3839-5.3917) 
    145  136.75-136.95 (5.3839-5.3917) 
    190  146.1-145.85 (5.75195-5.7421) 
    200  149.30-149.50 (5.8780-5.8858) 
    250  160.75-160.95 (6.3287-6.3366) 
    260  170.95-171.20 (6.7303-6.7402) 

  13. Select appropriate shim (3) from Table 41.

    Note: 130cc and 145cc pumps use one shim and one additional shim if needed for adjustment of lift-off clearance. This is shown in Table 39.

    Note: 190cc, 200cc, 150cc and 260cc pumps use the appropriate shims as shown in Table 41 to meet measurement (C) in Step 12.

    Table 41
    Adjustment Shim (3) 
    Displacement in cc  Shim thickness is mm (in)  Part Number 
    95  0.70 (0.0276)  130–7808 
    0.90 (0.0354) 130–7809 
    1.10 (0.0433) 130–7807 
    1.30 (0.0512) 130–7810 
    130  0.70 (0.0276)  6E-0723 
    0.90 (0.0354) 6E-0721 
    1.10 (0.0433) 6E-0720 
    1.30 (0.0512) 6E-0722 
    1.50 (0.0591) 6E-0724 
    145  0.70 (0.0276)  6E-0723 
    0.90 (0.0354) 6E-0721 
    1.10 (0.0433) 6E-0720 
    1.30 (0.0512) 6E-0722 
    1.50 (0.0591) 6E-0724 
    190  0.50 (0.0197)  179-6915 
    0.075 (0295) 179-6914 
    200  0.60 (0.0236)  5I-4271 
    0.80 (0.0315) 5I-4270 
    1.00 (0.0394) 5I-4269 
    1.20 (0.0472) 5I-4268 
    250  0.60 (0.0236)  6E-3844 
    0.80 (0.0315) 6E-3843 
    1.00 (0.0394) 6E-3842 
    1.20 (0.0472) 6E-3841 
    260  0.50 (0.0197)  165-9361 
    0.75 (0.0295) 165-9362 

  14. Remove the tooling and install the appropriate shim between the barrel and the spring group.

A20VLO

Note: The A20VLO adjustment of the rotary group procedure for the bearing preload and the lift-off clearance adjustment uses the same procedure as the A11VO/A11VLO.

Note: Perform calibration for each rotary group.

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