13
4. Install one ring (Fig. 3 Item 4) onto eccentric.
5. Install needle bearing (Fig. 3 Item 5) onto eccentric.
6. Insert hex cam (Fig. 3, Item 6) into piston ring assembly so
that it is centered and in contact with all piston heads. Make
sure the piston heads rest on a flat section of the hex cam.
7. Install piston ring assembly with the o-rings on the bottom
onto the top plate assembly being careful to slide hex
cam over eccentric bearing. The by-pass end cap needs
to be oriented over the by-pass port in top plate (note the
orientation of the bypass on Figure 1).
8. Place ring (Fig. 3, Item 4) onto eccentric assembly. The hex
cam may need to be pushed down so the ring is flush with
the top of the eccentric.
9. Place the gear pump assembly onto the eccentric assembly.
The gear pump may need to be rotated to fully engage the
shaft. Use caution to make sure the O-rings do not fall off the
gear pump during this operation. Once the gear pump is in
contact with piston ring rotate the gear pump until the inlet
filter is directly above the relief valve (Fig. 2, item 5).
Note
: Do not force the gear assembly onto the eccentric
assembly. If it requires a lot of force, check for misalignment
or damage.
10. Install the 12 gear pump mounting capscrews and torque
to 120-144 in-lbs. of torque using a crossing pattern.
11. On 6 piston pumps turn pump over and install 6 capscrews
(Fig. 2, item 6), tighten in an alternating sequence to a
120-144 in-lbs. of torque.
4.0 TEST PROCEDURE
4.1 Back Pressure Test
1. Remove the existing valve from the pump and install a
VM-2 valve in its place (NOTE: this is required due to the
presence of an internal check valve in most other valve
models).
2. Remove the pump assembly from the reservoir and place it
on a test bench, lying on its side so the bottom of the pump
can easily be observed.
3. Connect a 0-10,000 psi hand pump with a 0-15,000 psi
pressure gauge to the VM-2 outlet. Fully close the VM-2
valve.
4. Operate the hand pump to pressurize the pump to 85% of
its maximum rated pressure while observing for any system
leakage. Verify the pressure remains steady.
5. If the pump safety relief opens before reaching 85% of
maximum rated pressure, adjust the relief setpoint per 4.3
Safety Relief Valve Test.
6. If the pressure fails to hold steady at 85% of maximum
rated pressure, locate, isolate and correct the source of any
system leakage.
7. Release the system pressure and remove the hand pump,
pressure gauge and VM-2 valve. Replace the original valve
and restore the pump to its original condition.
TEST SPECIFICATION TABLE
Pump
Element
Number
By-pass Pressure
at Max. Amp
PSI [Bar]
Internal Safety
Relief Valve
PSI [Bar]
1st Stage
Flow
in
3
/rev [mL/rev]
2nd Stage
Flow
in
3
/rev [mL/rev]
By-pass Cap
Height
in [mm]
DC8143900
1625 [112]
10,300 [710] - 10,800 [745]
0.11 [1.8]
0.07 [1.15]
.92 [23.4]
DC9700900
850 [58.6]
10,300 [710] - 10,800 [745]
0.252 [4.13]
0.023 [0.38]
.99 [25.1]
DC9703900
(Not Applicable)
10,300 [710] - 10,800 [745]
0.023 [0.38]
0.023 [0.38]
.99 [25.1]
DC9704900
1250 [86.2]
10,300 [710] - 10,800 [745]
0.37 [6.06]
0.035 [0.57]
.95 [24.1]
DC9705900
1450 [100]
10,300 [710] - 10,800 [745]
0.192 [3.15]
0.035 [0.57]
.94 [23.9]
DC9706900
1450 [100]
11,700 [807] - 12,000 [827]
0.192 [3.15]
0.035 [0.57]
.94 [23.9]
DC9707900
1075 [74.1]
10,300 [710] - 10,800 [745]
0.252 [4.13]
0.035 [0.57]
.96 [24.4]
DC9708900
1075 [74.1]
11,700 [807] - 12,000 [827]
0.252 [4.13]
0.035 [0.57]
.96 [24.4]
DC9709900
(Not Applicable)
10,300 [710] - 10,800 [745]
0.035 [0.57]
0.035 [0.57]
.99 [25.1]
DC9710900
1125 [77.6]
10,300 [710] - 10,800 [745]
0.479 [7.85]
0.07 [1.15]
.96 [24.4]
DC9713900
(Not Applicable)
10,300 [710] - 10,800 [745]
0.07 [1.15]
0.07 [1.15]
.99 [25.1]
DC9714900
1050 [72.4]
5300 [365] - 5600 [386]
0.37 [6.06]
0.07 [1.15]
.99 [25.1]
DC9715900
2425 [167.2]
10,300 [710] - 10,800 [745]
0.252 [4.13]
0.07 [1.15]
.85 [21.6]
DC9717900
1125 [77.6]
5300 [365] - 5600 [386]
0.192 [3.15]
0.035 [0.57]
.96 [24.4]
DC9718900
(Not Applicable)
5300 [365] - 5600 [386]
0.035 [0.57]
0.035 [0.57]
.99 [25.1]
DC9719900
(Not Applicable)
5300 [365] - 5600 [386]
0.07 [1.15]
0.07 [1.15]
.99 [25.1]
DD1123900
1625 [112]
10,300 [710] - 10,800 [745]
0.192 [3.15]
0.07 [1.15]
.92 [23.4]
DD1491900
1425 [98.3]
5300 [365] - 5600 [386]
0.11 [1.80]
0.023 [0.38]
.93 [23.6]
DD1505900
850 [58.6]
11,700 [807] - 12,000 [827]
0.252 [4.13]
0.023 [0.38]
.99 [25.1]
DD1506900
1250 [86.2]
11,700 [807] - 12,000 [827]
0.37 [6.06]
0.035 [0.57]
.95 [24.1]
DD1507900
1125 [77.6]
11,700 [807] - 12,000 [827]
0.479 [7.85]
0.07 [1.15]
.96 [24.4]
NOTE: the pump element number is stamped into the top plate.
