Commercial G102 Pump Valve Instruction Manual
- June 13, 2024
- Commercial
Table of Contents
Commercial G102 Pump Valve
Introduction
Commercial’s G101 and G102 pump valve assemblies are compact power sources for smaller dumptrucks. These units are based on Commercial’s well-proven P30 gear pumps and produce flows of 21 gpm (1 1/2″ gears) to 29 gpm (2″ gears) at 1800 rpm. Maximum working pressure is 2500 psi and maximum speed is 2400 rpm.
cleanliness
The most common cause of premature pump failure is dirty oil. Modern hydraulic
components require very close tolerances to operate efficiently at high
pressures. Contaminants, no matter how small, cause wear and decrease the life
of the piece of equipment. Make sure all components are clean when they’re
installed and that regular maintenance practices keep the oil clean.
options
- Spring return-to-neutral or detent spool actuation.
- G 1 01 remote mount units can be driven in either rotation.
- G 102 direct mountings: SAE “B” 4-bolt SAE “B” 2-bolt Cloverleaf 4-bolt Please specify the direction of rotation when ordering G102 direct mount units.
- Choice of two- or three-line installations.
These Warnings Apply to All Pump / Valve Units
- A device to lock the control lever in the neutral position must be installed. Pump / valve units with- out a lockable control lever may allow the dump bed to rise unintentionally while in transit. Failure to provide such a lock may lead to loss of vehicle control, accidental injury and/or property damage.
- Failure to disengage the PTO from driving the pump/valve when in transit may allow the dump bed to rise unintentionally. This may lead to loss of vehicle control, accidental injury and/or property damage.
- Commercial’s pump/valves are equipped with a neutral stop device for those applications using a pull-out cable. This device allows the pull-out cable to move the valve spool from the raise to the neutral position only. Since shockloading in the cable is possible, it is essential that a spring (Commercial’s part no. 391-3581-854 or equal) be incorporated in the pull-out cable hookup. Failure to do so could result in breakage of the neutral stop device and could lead to injury. We recommend that the cable be fully enclosed and directly in line with the spool.
- Never work under a raised dump bed without first securely blocking the bed to prevent its accidental lowering.
- 3-line installations are recommended whenever possible. 3-line circuits consist of a pump inlet line, a line to the cylinder and a return line to tank. A sleeve must be installed in the pump’s inlet to allow oil to circulate through the unit and return to tank when running in neutral. Lower operating temperatures and the ability to install a return-line filter are two advantages of a 3-line circuit. Be sure the return line is always below the oil level in the reservoir. 2-line installations are for intermit- tent operation only.
If you do not understand these warnings or have any questions about any of them, contact your Commercial Intertech distributor or the Product Support Group at Commercial. Phone 216-746-8011 or Fax 216-746-1148
lubrication and oil recommendations
All parts are lubricated by the hydraulic oil in the circuit. Particular attention must be paid to keep the oil in the system clean. Whenever there is a pump failure and there isreason to feel that metal particles may be in the system, the oil must be drained, the entire system flushed clean and any filter screens thoroughly cleaned or replaced. New oil should be supplied for the entire system. Oil suitable and recommended for use in circuits involving Commercial’s pumps and motors should meet the following specifications.
viscosity:
- 50 SSU minimum @ operating temperature
- 7500 SSU maximum @ starting temperature
- 150 to 225 SSU @ 100°F (37.8°C) (generally)
- 44 to 48 SSU @ 210°F (98.9°C) (generally)
approximate SSU at …
viscosity index: 90 minimum
aniline point:
- + 175° (80°C) minimum
recommended additives:
- Foam Depressant Rust and Oxidation Inhibitors
other desirable characteristics:
- Stability of physical and chemical characteristics.
- High demulsibility (low emulsibility) for separation of water, air and contaminants.
- Resistant to the formation of gums, sludges, acids, tars and varnishes.
- High lubricity and film strength.
general recommendations:
A good quality hydraulic oil conforming to the characteristics listed is
essential to satisfactory performance and long life of any hydraulic system.
Oil should be changed on regular schedules in accordance with the
manufacturer’s recommendations and the system periodically flushed. Oil
temperature in reservoir must not exceed 200°F (93.3°C) with a maximum
temperature of 180°F (82.2°C) recommended. Higher temperatures will result in
rapid oildeterioration. Reservoir capacity should equal that of the
cylinder(s) plus 20 gallons or be approximately 1 1/2 times the output of the
pump. Oil poured into the reservoir should pass through a 100 mesh screen.
Pour only clean oil from clean containers into the reservoir.
3-line installations ONLY
A 1 00 mesh screen may be used in the suction line. If a suction filter is
used, it should be of sufficient size to handle twice the pump’s rated flow.
It must be cleaned and checked regularly to avoid damage due to contamination
and cavitation. Always mount the pump lower than the hydraulic reservoir to
ensure the inlet will be flooded with a good supply of oil.
normal temperatures:
Ambient. 0°F (-18°C) to 100°F (37.8°C)System. 100°F (37.8°C) to 180°F (82.2°C)
Be sure your oil is recommended for the temperatures you expect to encounter.
cold weather operations:
Oils for use in cold weather should have a viscosity not exceeding 7500 SSU at
the minimum start-up temperature. A pour point of at least 20°F below start-up
temperature is recommended. Start-up procedures should allow for a gradual
warm-up until the oil reaches a reasonably fluid state.
the use of other oils:
- Automatic Transmission Fluid (ATF): General experience here has been satisfactory; however, ATF oils are sometimes too expensive for normal use in hydraulic systems.
- Diesel Fuel or Kerosene (Coal Oil): Sometimes used as dilutants for cold weather operations but are not recommended as they are not sufficiently refined products.
- DO NOT USE ANY FIRE RESISTANT FLUIDS OR NON-PETROLEUM OILS WITHOUT CONSUL TING OUR PRODUCT SUPPORT DEPARTMENT.
- These suggestions are intended as a guide only. OBTAIN YOUR FINAL OIL RECOMMENDATIONS FROM YOUR OIL SUPPLIER.
recommended start-up procedure for new or rebuilt pump or motor
Before connecting any lines to the pump pour a small quantity of clean oil in the inlet port to provide initial lubrication. After connecting the lines and mounting the replacement unit, operate the pump at least two minutes at zero pressure at lowest possible rpm. During this break-in period, the unit should run free and not develop an excessive amount of heat. If the unit operates properly, speed and pressure can then be increased to normal operating setting of 2000 psi.
tool list
- Arbor Press
- Bearing Puller (Owatonna Tool Co. MD-956 or equivalent)
- Clean Lintless Cloths
- Deburring Tool (an old file with the cutting teeth ground off)
- Machinist’s Hammer
- Feeler Gage
- Soft Hammer
- Permatex™ Aviation Form-AGasket No. 3 Non-hardening Sealant or Equivalent
- Medium Grit Carborundum Stone
- Oil and Grease
- Snap Ring Pliers
- Prick Punch
- Sharp Razor Blade
- Scale (1 /32″ or 1/64″ graduations)
- Small Screwdriver
- 8″ Adjustable Wrench
- Torque Wrench
- Vise with 6″ Minimum Open Spread
- Bar for Lip Seal Installation (use 1 5/8″ dia. by 2″ bar)
- Special Steel Sleeve
A seal remover tool can be easily made from an old screwdriver. Heat the blade and bend the tip as shown. Grind the tip to fit the notch behind the shaft seal.
- All external surfaces must be free of scratches and burrs.
plu bing options
two-line installation
Generally used for intermittent operation. When the spool is in neutral, the
unit recirculates oil internally. Two lines are used, one to cylinder and one
to the tank.
three-line installation
3-line circuits are recommended whenever possible. With the spool in neutral,
oil circulates through the pump and returns to tank. 3-lines are used, one to
tank, one inlet line and one to the cylinder. This circuit requires a sleeve
in the pump’s inlet (P/N) 391-3283-052) This special steel sleeve can be made
from bar stock and is used to prevent damage when inserting the drive shaft
through the lip seal. The drawing gives details for making this tool.
disassembly
-
Wash and wipe all dirt from the outside of the unit. Mark the castings to simplify reassembly.
-
(G101 ONLY) Remove the key from the drive shaft and save for reassembly.
-
Grip the valve end of the unit in a large vise with the drive shaft(s) up. If the pump is a G 102, remove the snap ring, spacer and seal retainer. If a G 101 , remove the snap rings from both drive shafts.
-
Turn the pump end-for-end and grip the shaft end cover in the vise.
NOTE: If the valve spool or relief valve is not to be removed, go to step -
Be sure that the valve spool moves easily in the bore. If the spool is detented, make sure the detent holds.
-
Remove the relief valve cartridge from the valve assembly. Maintenance instructions are on page 6. Keep dirt and foreign matter out of the open end of the cartridge.
-
If spool “O” rings are to be replaced, you must remove the spool from the housing. Methods differ depending on the type of operator: detent
-
Move the spool to the neutral detent position. Remove the detent retaining cap, lock washer, spring, detent ball and the end cap. A pen magnet works well to remove the detent ball. Be careful not to lose the spring or ball.
-
Remove the two cap screws and slide the spool end cap off of the spool. Remove the retainer plate. spring return
-
Remove the two socket head cap screws from the spool end cap and slide the cap off of the spool.
-
Remove the two retaining rings, the two spring guides, spring and its retainer.
CAUTION: The spring is compressed. From this point, instructions are the same for both types of operators. -
Remove the two socket head cap screws from the bracket over the rear of the spool and slide the bracket over the end of the cap. Remove the spiral pin from the spool and slide off the spool end cap.
-
Remove any dirt and paint from the spool.
-
Push the spool through the bore to be sure it slides freely. Remove the spool. If the spool drags in the bore, inspect the spool for nicks or burrs. If possible, remove these with 330 or finer emery or crocus cloth. If the spool continues to drag, it may be bent or the spool bore may be damaged. Spools are hone-fitted to their individual housings. Therefore, damage to either the spool or housing means the entire valve must be replaced.
-
Remove the “O” rings from both ends of the bore and discard. Check “O” ring groove for any foreign material.
-
-
Remove cap screws with a sturdy socket and breaker bar and lift the valve housing from the assembly. Remove thrust plate if it remains attached to the valve housing.
-
Push upward on the end of the drive shaft(s) until gears can be lifted out of gear housing.
-
Using two pry tools or screwdrivers, separate the gear housing from the shaft end cover. Be careful not to damage machined surfaces. Remove the gasket seals from their grooves and discard. Remove the thrust plate from housing bore. Discard the rubber pocket seals.
-
Use the bent pry tool or a screwdriver to tap the shaft seals out of G101 bores or the shaft seal out of the G102. Discard the seals.
-
Remove bearings from the shaft end cover and valve housing with a bearing puller. The high pressure ring seals can then be lifted out and inspected for wear. Wash all component parts in solvent and blow dry prior to inspection.
component inspection
Wear on component parts will often indicate what problems existed while the
unit was in operation. Listed below are major components and general rules to
help you determine acceptable wear limits.
gear housing
Pressure pushes the gears against the housing on the low pressure side. As the
hubs and bearings wear, the cut-out becomes more pronounced. Excessive cut-out
in a short period of time indicates excessive pressure or oil contamination.
Place a straight-edge across bore. If you can slip a .005″ feeler gage under
the straight edge in the cutout area, replace the gear housing. The G 101/G102
gear housing can not be ”flopped” because the high and low pressure· sides are
not interchangeable.
drive shafts/gears
Replace if there is excessive wear in the ring seal areas or at the drive
coupling .. 002″ wear is the maximum allowable. Any scoring on gear hubs
detectable by touch, or wear in excess of .002″ necessitates replacement.
Scoring, grooving or burring of outside diameter of teeth requires
replacement. Nicking, grooving or fretting of tooth surfaces also necessitates
replacement. The gears in the G101/G102 are matched sets. Damage to either
gear means both gears must be replaced with another matched set.
bearings
If the gears are replaced, replace the bearings. We recommend replacing
bearings during any major repair or rebuild. Worn bearings are indicated by
rollers falling out of the cage, pitting or metal flaking from the roller tips
or the inside race. Bearings should fit into the bore with a light press fit,
however, a neat hand fit is allowable. If bearings do not fit snugly, the
bearing bores may be worn and the casting should be replaced.
thrust plates
The thrust plates seal the oil at the sides of the gears. Wear here will allow
internal slippage, allowing oil to bypass within the pump and decreasing
efficiency. 002″ maximum wear is allowable. Replace thrust plates if they are
scored, eroded, discolored or pitted. Check center of thrust plates where the
gears mesh. Erosion here indicates oil contamination. Pitted thrust plates
indicate cavitation or oil aeration. Discolored thrust plates indicate
overheating, probably insufficient oil or traveling with PTO engaged, a
dangerous practice.
seals and gaskets
Replace all rubber and polymer seals whenever repairing pump, including all
“O” rings, pocket seals behind the thrust plates, shaft seals and gasket
seals.
valve repairs
Repairs to the valve assembly are limited to replacing worn spool seals and
relief valve maintenance detailed on page 6. No repair should be attempted on
the spool itself except the light polishing as indicated in disassembly step
6.
combination relief valve/check valve
Major wear points are the check poppet, internal poppet and seat. The relief
valve can be disassembled and cleaned in solvent and blown dry. If parts are
worn or the operation of the relief valve is suspect, replace the cartridge.
assembly
Always Use Genuine Commercial lntertech Replacement Parts
-
Wash parts in solvent. Blow dry.
-
Clean shaft seal bores with fine emery cloth to remove any burrs or old sealant. Apply Permatex™ Aviation Form-aGasket #3, non-hardening sealant or equivalent to the O.D. of the seals. Press the seals into the bores with an arbor press. Wipe any excess sealant off the O.D. of seal. Install snap rings.
-
If bearings were removed at disassembly, place the high pressure ring seals in each bearing bore with flat side down. Press new bearings into their respective bores in the shaft end cover and valve housing using a flat bar and arbor press. The bearings will bottom out in the casting and should protrude equally from the machined surface.
-
Place the shaft end cover in a vise with the bearings facing up. With a razor blade, cut the two center pocket seals 3/ 16″ long from the pocket seal strip and insert them in the thrust plate. Use light grease to hold seals in place.
CAUTION: The gear housing has arrows cast into the surface to indicate rotation direction. The units must be assembled with the arrows pointing toward the valve. -
With the pocket seals facing down, place the thrust plate over the bearings in the shaft end cover. Tap thrust plate with a soft hammer to about 1 /32″ from the machined surface. Cut four pocket seals approximately 1/4″ long from the pocket seal strip. Insert one pocket seal into each of the slots in the thrust plate. Push each pocket seal all the way in so that it touches the roller bearings. Tap the thrust plate down firmly against the machined surface with a soft hammer. Use a sharp razor blade to trim exposed end of the pocket seal square and flush with the thrust plate. Repeat the procedure for the valve housing thrust plate.
-
Insert the end of the drive shaft into the steel sleeve (see Tool List). Lightly grease the drive shaft and sleeve. Insert the integral gear and drive shaft with sleeve into the shaft end cover with a twisting motion. Be careful not to damage the lip seal. Push down carefully until the gear rests against the thrust plate. Remove the steel sleeve. Insert the other gear.
-
Lightly coat the gasket seals with grease and install them in the gasket seal grooves in the gear housing. Slip the gear housing over the gears.
-
Seat the valve housing assembly on the gear housing. Be sure not to pinch the gasket seals. A light tapping with a soft mallet may be needed to seat the casting.
-
Install the four washers on the cap screws and thread into the shaft end cover. Tighten the cap screws cross-corners to 2400 in.fib. Check for free shaft movement by turning shafts with a wrench.
-
Install the spool “O” ring into the groove in the valve at the end opposite from the detent housing. Apply a light coating of clean hydraulic oil to the spool. Insert the spool into the housing from the detent cap end. Be careful not to cut the “O” ring. Push the spool through the housing.
-
Apply a light coating of oil to the second spool “O” ring and install it over the spool and into its groove behind the retainer plate.
-
Slip the spool end cover over the rear spool clevis. Align the spool’s pineye with the slot in the spool end cap and insert the spirol pin. Install the bracket with two socket head cap screws.
-
detent installation:
- Slide the seal retainer plate over the front of the spool. Slide the end cap on and attach it with two socket head cap screws.
- Install the detent ball, spring, washer and detent retainer.
-
spring return installation:
- Slide the seal retainer plate over the front of the spool. Install the rear spring retainer, rear spring guide. spring and front spring guide.
- Compress the spring and install the front spring retainer.
- Slide on the end cap and attach it with two socket head cap screws.
-
Install the relief valve in the housing.
-
If the G101/G102 is to be used in a 3-line installation, insert the optional sleeve in the inlet port. Be sure to remove the pipe plug from the return port.
G101/G102 relief valve maintenance
Commercial’s G101/G102 pump/ valve units have unique internal passages in the valve assembly that allow the relief valve to function as a main and a port relief and a load-hold check. All mechanical structures integrated with the hydraulic system are consequently protected from overload and excessive shock stresses. Figure 2 shows the arrangement of internal parts and the location of the serviceable seals. If contamination lodges between the poppet and seat, the relief valve will leak internally and prevent the cylinder from being pressurized or allow the load to drift.
The relief valve can be cleaned by removing the hex cap, floating seat, shims, spring and plunger. These components, plus the exposed seat area, can then be flushed with solvent and blown dry with air. The load-holding check seats on a machined face in the valve housing. The relief valve cartridge must be removed to inspect or to clean the check’s seat area. If cleaning or replacing seals fails to correct relief valve problems, the cartridge should be replaced. All G101 / G102 units have a tubular wire screen which fits snuggly over the poppet end of the relief valve. The screen (P/N 391-2781-016) greatly reduces the possibility of any contamination reaching the seat area.
All relief valves in these units are
factory pre-set at 2000 psi. The table below has been developed to aid in the
readjustment of these relief valves if it becomes necessary.
Factory pressure setting 2000 psi
Note: Due to normal manufacturing tolerance, the actual pressure settings obtained by these adjustments may vary slightly from those shown in the table. Always check pressure setting with an accurate gage.
parts list
Caution:
- Exploded view is not to scale and may not be pictorially correct.
- Exploded view and attached parts list will not be kept up to date. Refer to current engineering drawing for bill of materials.
- All repairs should be made in accordance with Commercial’s service instructions.
- Use only genuine Commercial Intertech parts for repairs.
G102 Shaft End Parts List Replaces Items 1 Through 8 in G101 Parts List Below
G101/G102 service kits
Shaft seal service kits and repair kits are available for the G 101 / G102 pump/valves. Parts included in these kits are shown below. Refer to exploded drawing on page 7 for location of parts.
neutral stop cable spring
For applications using a pull-out cable This spring, attached to the dump body
bed, is required in the cable assembly to protect the spool cap of the neutral
stop device from pull shocks when the dump body reaches full extension. It
will work with C101/C102, C101 Airshift and G 101 /G 102 pumps
Neutral Stop Cable Spring (P/N 391-3581-854)
troubleshooting
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ACTON, ON L7J 2M6 CANADA
Commercial Intertech Ltd. 6 Commerce Crescent, P.O. Box 450
- Phone: 519-853-0770
- Facsimile: 519-853-3837
FRANCE
Commercial Hydraulics Astron S.A.R.L. BP 73, 20, rue Pierre Mendes
- France, Torey 77202 Marne La Vallee
- Cedex 01
- Phone: 33-1-6462· 1100
- Telex: 693-737 F
- Facsimile: 33·1-6462-1093
Designers and Manufacturers of Fluid Power Components, Worldwide; Pressed Metal Products, North America; Filtration and Separation Products, Worldwide; and Pre-Engineered Buildings; Europe.
References
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