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

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Introduction

© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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 Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For 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 Caterpillar 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 Caterpillar equipment that incorporates Bosch Rexroth hydraulic piston pumps and motors.

Important Safety Information

Illustration 1	g02139237

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. Caterpillar 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 Caterpillar 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.

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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 2	g00008666

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.

Caterpillar 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. Caterpillar 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:

(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 Caterpillar Equipment, it would not be feasible to list all of the associated Caterpillar part numbers. The identification refers to the family of the motor or pump, the displacement in cubic centimeters, and the series.

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 3	g01009274
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 4	g01009308
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 5	g01009306
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 6	g01118952
"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 7	g01011046
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
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   Illustration 8	g01012576

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.

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

Illustration 9	g01118959
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).

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 10	g01139759
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.
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   Illustration 11	g01009398
   The arrangement of the 6 cup springs for A2FM/A2FE motor

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   Illustration 12	g01010870
   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.

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    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.
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    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 13	g00992929
"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 14	g01150537
(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).

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 15	g01011150
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.

    Show/hide table

    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.
    Show/hide table

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

Illustration 17	g01119004
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.
   Show/hide table

   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)

   Show/hide table

   (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.

    Show/hide table

    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.

    Show/hide table

    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 18	g01009509
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 19	g03779116
FT-3275 is required for bearing preload adjustment. Dimensions in millimeters.

Illustration 20	g03780123
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.
   Show/hide table

   Illustration 21	g03780623
   (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 9.a.

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

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

      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 9.c and Step 9.d.

    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 22	g03798865
(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).
   Show/hide table

   Illustration 23	g03780154
   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 28/80/107/200 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 24	g01009587
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.

   Show/hide table

   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).
   Show/hide table

   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
   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).
   Show/hide table

   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 25	g01117795
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.

   Show/hide table

   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).
   Show/hide table

   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

   Show/hide table

   (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 26	g01117802
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

   Show/hide table

   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.
   Show/hide table

   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

   Show/hide table

   (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 27	g01009853
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 28	g01119047
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.
   Show/hide table

   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).

    Show/hide table

    Illustration 29	g01011324
    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.

    Show/hide table

    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.
    Show/hide table

    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 30	g01010506
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 31	g01119054
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.
   Show/hide table

   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

   Show/hide table

   Illustration 32	g01150541
   (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.
    Show/hide table

    Illustration 33	g01010474

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.
    Show/hide table

    Table 28

    Explanation of Dimensions
    Dimension	Description
    K	Measurement from Illustration 33
    L	Lift-off clearance
    M	Ideal center pin disc thickness
    C	Center pin disc thickness
    X	Difference between ideal center pin disc thickness (M) and center pin disc thickness (C)
    S	Shim thickness used during measuring procedure(1)
    Z	Required shim thickness for proper lift-off adjustment

    Show/hide table

    (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.

    Show/hide table

    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.
    Show/hide table

    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 34	g01010090
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 35	g01150546
(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.

   Show/hide table

   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.
   Show/hide table

   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
    Show/hide table

    Illustration 36	g01012323

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 37	g01010155
(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.

   Show/hide table

   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.
   Show/hide table

   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.
    Show/hide table

    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 38	g01010213
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.
   Show/hide table

   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).

    Show/hide table

    Illustration 39	g01011324
    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.

    Show/hide table

    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)

    Show/hide table

    Illustration 40	g01119059
    (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.

    Show/hide table

    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 (0.3839)	5I-8405
    	9.85 (0.3878)	5I-8406
    	9.95 (0.3917)	5I-8407
    	10.05 (0.3957)	5I-8408
    	10.15 (0.3996)	5I-8409
    	10.25 (0.4035)	5I-8410
    	10.35 (0.4075)	5I-8411
    	10.45 (0.4114)	5I-8412
    	10.55 (0.4154)	8I-8413
    200	12.30 (0.4843)	177-2509
    	12.40 (0.4882)	177-2508
    	12.50 (0.4921)	177-2507(1)
    	12.60 (0.4961)	177-2506
    	12.70 (0.5000)	177-2505
    	12.80 (0.5039)	177-2504(1)
    	12.90 (0.5039)	-(1)
    	13.00 (0.5039)	-(1)
    	13.10 (0.5039)	-(1)
    	13.20 (0.5039)	-(1)
    	13.30 (0.5039)	-(1)
    	13.40 (0.5039)	-(1)

    Show/hide table

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

Illustration 42	g01119061
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.
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   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	-

   Show/hide table

   (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.

    Show/hide table

    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.

    Show/hide table

    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
    	0.08 (0.0315)	5I-4270
    	1.00 (0.0394)	5I-4269
    	1.20 (0.0472)	5I-4268
    250	0.60 (0.0236)	6E-3844
    	0.08 (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.