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US Selected Assemblies Catalogue #999-901-192 243 1 2 4 3 General Information Page Cartridge Control Options 244 Cartridge Control Kits 245 Cavity Plugs 246 Solenoid Electrical Connector Options 248 Pressure Drop Data Chart 249 Cartridge Cavities and Cavity Tools 250 244 US Selected Assemblies Catalogue #999-901-192 General Information CARTRIDGE CONTROL OPTIONS General Purpose Controls L Standard Screw Adjustment O-ring seal on adjust screw. Adjust screw positively retained. Overset protection-pilot spring cannot go solid. K Handknob with Lock Knob Handknob and lock knob added to L control. Sun handknob kits for field conversion are available. See cartridge control kits. O Handknob with Panel Mount Special threaded cartridge hex body with panel nut for mounting cartridge through access hole in control panel. Handknob and lock knob included. Panel Hole: Series 1 cartridges .75” dia. Series 2 cartridges 1.00” dia. C Tamper Resistant Factory Set Steel cover press-fits onto L control cartridge shoulder. Valves may be ordered in this configuration. Specify pressure setting on order. Setting stamped on cartridge hex. Kits for field conversion are available. See cartridge control kits. Key Lock Kit Optional adjustment Key Lock Cover Kit for L controls allows adjustment to be locked with a key to prevent unauthorized changes in valve setting. Adjustment easily accessible when lock assembly is removed. Requires replacement of standard locknut with special locknut which accepts assembly, and new wire stop ring for overset protection. H Calibrated Handknob with Detent Lock Fully calibrated handknob for flow control cartridges. 40 radial calibrations per turn. Moveable zero indicator. (Minor disassembly required.) Rising detented locking collar positively locks adjustment knob against vibration or accidental tampering. Any desired setting may be recorded and repeated. U.S. Patent #4,577,831 Diameter 1.13” Dia. 1.38” Dia. 1.62” Dia. 1.62” Dia. Series 1 2 3 4 NCCB NCEB NCFB NCGB NCCC NCEC NCFC NCGC NFCC NFDC NFEC NFFC NFCD NFDD NFED NFFD FDBA FDCB FDEA FDFA Special Purpose Controls (for use in systems where adjustment is seldom changed after installation) J Socket Head Set Screw with Cap F Wrench Adjustment Stem seal O-ring under locknut. Adjustment screw is not retained. No overset protection. Stem seal O-ring under locknut. Adjusting screw is not retained. Overset protection-pilot spring cannot go solid. Counterbalance Valves L Standard Leakproof Screw Adjustment. O-ring seal on adjust screw. All Sun counterbalance cartridges are built with a leakproof adjustment (O-ring seals on the adjusting screw) but are not designed for frequent adjustment in the field. Cartridges that are factory pre-set by Sun to a customer specified pressure setting are available and can be installed directly on a machine without the need for further adjustment. C Tamper Resistant Factory Set See C Control description above. 5/32” Hex 9/16” Hex 5/32” Hex 2.44" 1.66" 3.12" to remove key or cover Dia. Rising Stem Counts Full Turns Locking Collar Zero Indicator 5/32” Hex 1.17” diameter 1.25” diameter .09” .30” Panel Hole 5/32” Hex 9/16” Hex Series 1, 2, 3: 5/32" Hex Series 4: 7/32" Hex Series 1, 2, 3: 9/16" Hex Series 4: 3/4" Hex US Selected Assemblies Catalogue #999-901-192 245 General Information CARTRIDGE CONTROL KITS Service Kit Number Description Use specifically with Control/Cartridge Description Notes Adjustment Screw Kit 991-006 All F controls To assure a complete seal on the stem - release all pressure on the cartridge after setting. Then... tighten locknut (and cap, on J). Adjustment Screw Kit 991-010 All J controls Tamper Resistant Cover 991-000 991-004 991-001 991-002 991-003 For all Sun cartridges with L adjustment Series 0 - 3/4” (19,0 mm) hex hex Series 1 - 7/8” (22,2 mm) hex Series 2 - 1 1/8” (28,6 mm) hex Series 3 - 1 1/4” (31,8 mm) hex Series 4 - 1 5/8” (41,0 mm) hex Tamper Resistant Cover 1. Adjust valve to desired setting and tighten locknut. 2. Using an arbor press or a soft hammer, install cover until it seats on cartridge hex. 3. Cover is a press fit on cartridge shoulder. Key Lock Kit 993-008 For all Sun cartridges with L adjustment (except Series 0 and counterbalance cartridges). 1. Remove original wire stop ring and locknut. 2. Thread on the adapter locknut and install new wire stop ring through slot provided. 3. Adjust valve to desired setting and tighten adapter locknut. 4. Slide lock assembly over adapter, lock and remove key. K Handknob Kit 991-211 Use this kit to adapt all L controls to K controls (except Series 0 and counterbalance cartridges). Only cartridges date stamped “41” or later and originally supplied with plastic knobs. Lock knob snaps onto locknut furnished on cartridge. 991-222 K control for Series 0 Panel Handknob Kit 991-215 O controls All Series 1 cartridges 7/8” (22,2 mm) hex M20 thread Panel Handknob Kit 991-216 O controls All Series 2 cartridges 1 1/8” (28,6 mm) hex 1”-14 thread H Calibrated Handknob Kit H controls All series of flow controls Only for cartridges originally supplied with an H handknob. Valves can not be modified in the field. Note: The H control is Only available for the cartridges shown to the left. 991-219 FDCB, NCEB, NCEC,NFDC, NFDD only 991-220 FDEA, FDFA, NCFB, NCFC, NCGB, NCGC, NFEC, NFED, NFFC, NFFD only 991-221 FDBA, NCCB, NCCC,NFCC, NFDC only Lockwire 911-012 All M, Q and R controls (except solenoid operated cartridges). Adjustment Screw Kit 991-112-003 Viton 991-112-007 Buna-N For cartridge models: CKCA L**CKCD L** CKCB L**CPCA L** CKCC L** Only cartridges date stamped “62” or earlier.Adjustment Screw Kit 991-212-003 Viton 991-212-007 Buna-N For cartridge models: CKEA L**CKED L** CKEB L**CPEA L** CKEC L** Cap Locknut Seal Adjust Screw Adjust Screw Locknut Seal For all Sun cartridges with L-adjustment Cover Wire Stop Ring Lock Assembly Key Adapter Locknut Handknob Assembly Lock Knob Handknob Assembly LockKnob Handknob Lockring O-ring ExsistingCartridge Locking Wire Lead Seal Manual Release Screw Locknut Seal Back-up Ring 246 US Selected Assemblies Catalogue #999-901-192 General Information CAVITY PLUGS It is sometimes desirable to remove a Sun cartridge valve and still maintain the integrity of the hydraulic system. This may be necessitated by the need to flush a system after repairs or a piping change, or to change an operating function in the circuit. For these requirements, Sun offers two styles of cavity plugs - all ports blocked and main ports open to flow. Plugs for Two Port Cavities: All Ports Open All Ports Blocked Series Cavity Cavity PlugModel Code Cavity Plug Model Code P T-8A XAOA-XX* XACA-XX* 0 T-162A XZOA-XX* XZCA-XX* 1 T-10A XFOA-XX* XFCA-XX* T-13A XGCA-XX* 2 T-3A XCOA-XX* XCCA-XX* T-5A XDCA-XX* 3 T-16A XIOA-XX* XICA-XX* 4 T-18A XKOA-XX* XKCA-XX* Plugs for Three Port Cavities Ports 1 to 2 Open Port 3 Blocked All Ports Blocked Series Cavity Cavity PlugModel Code Cavity Plug Model Code P T-9A XAOB-XX* XACB-XX* 0 T-163A XZOB-XX* XZCB-XX* 1 T-11A XEOA-XX* XECA-XX* 2 T-2A XBOA-XX* XBCA-XX* 3 T-17A XHOA-XX* XHCA-XX* 4 T-19A XJOA-XX* XJCA-XX* Plugs for Four Port Cavities (Internal Locating Shoulder) Ports 1 to 2 Open Port 3 and 4 Blocked All Ports Blocked Series Cavity Cavity PlugModel Code Cavity Plug Model Code 1 T-21A XMOA-XX* XMCA-XX* 2 T-22A XNOA-XX* XNCA-XX* 3 T-23A XPOA-XX* XPCA-XX* 4 T-24A XQOA-XX* XQCA-XX* *Insert in the seventh position model code digit N to order Buna-N seals or V to order Viton seals. 2 1 1 2 1 2 3 1 2 3 1 2 4 3 1 2 4 3 US Selected Assemblies Catalogue #999-901-192 247 General Information CAVITY PLUGS Plugs for Four Port Cavities (External Locating Shoulder) All Ports Open All Ports Blocked Series Cavity Cavity Plug Cavity PlugModel Code* Model Code* 1 T-31A XFOA-XX* XRCA-XX* 2 T-32A XCOA-XX* XSCA-XX* 3 T-33A XIOA-XX* XTCA-XX* 4 T-34A XKOA-XX* XVCA-XX* Plugs for Six Port Cavities Ports 1, 2, 3 and 4 Open Ports 5 and 6 Blocked All Ports Blocked Series Cavity Cavity Plug Cavity PlugModel Code* Model Code* 1 T-61A XMOA-XX* XRCC-XX* 2 T-62A XNOA-XX* XSCC-XX* 3 T-63A XPOA-XX* XTCC-XX* 4 T-64A XQOA-XX* XVCC-XX* Cavity Adaptor (Adapts Waterman 12-2 Cavity to the Sun T-8A Cavity) All Ports Open Cavity Cavity Plug Model Code* 12-2 XAAA-8X* *Insert in the seventh position model code digit N to order Buna-N seals or V to order Viton seals. 1 2 4 3 1 2 4 3 1 2 4 3 5 6 1 2 4 3 5 6 2 1 248 US Selected Assemblies Catalogue #999-901-192 General Information SOLENOID ELECTRICAL CONNECTOR OPTIONS Pilot Flow Solenoid Valves: DAAA, DBAA Full Flow Solenoid Valves: DLDA, DTDA, DMDA, DNDA ISO / DIN 43650 SAE J858-A Twin Lead Description Coil onlypart number Coil only part number Coil only part number 115 V AC 50/60 Hz 760-211 N/A N/A 230 V AC 50/60 Hz 760-223 N/A N/A 6 V DC 760-206 760-506 N/A 12 V DC 760-212 760-512 760-712 24 V DC 760-224 760-524 760-724 36 V DC 760-236 N/A N/A 48 V DC 760-248 N/A N/A ISO / DIN 43650 AMP® Junior Timer Twin Lead Description Coil only part number Coil only part number Coil only part number 115 V AC 50/60 Hz 770-211 N/A N/A 230 V AC 50/60 Hz 770-223 N/A N/A 12 V DC 770-212 770-612 770-712 24 V DC 770-224 770-624 770-724 48 V DC 770-248 770-648 770-748 AMP® is a registered trademark. US Selected Assemblies Catalogue #999-901-192 249 General Information ORIFICE PRESSURE DROP DATA No allowance has been made for viscosity effects, or regain of pressure downstream. 3 47 8 5 8 7 16 3 8 4000 3000 2500 2000 1500 1000 500 200 100 50 25 10 0 Pr es su re D ro p – ps i 1 2 3 4 5 6 7 8 9 10 1 64 1 32 1 16 3 32 1 8 5 32 3 16 7 32 1 4 5 16 3 8 7 161 2 Pr es su re D ro p – ps i 4000 3000 2500 2000 1500 1000 500 200 100 50 25 10 0 10 20 30 40 50 60 70 80 90 100 3 32 1 8 7 32 1 4 5 16 1 2 9 16 These charts are based on the formula: Where: Q = Flow in Cu. Ft. per Sec. C = Orifice Coefficient A = Area of Orifice in Sq. Ft. H = Pressure Head in Ft. Specify Gravity of Fluid = .895 This equation becomes Q(GPM) = Q ∅ C ± A ± 2gH Pressure Drop (psi) when C ∅ 0.624.12 ± A(sq.in.) ± Orifice diameter, inches Orifice diameter, inches 5 32 3 16 1 Flow – GPM Flow – GPM NOTES:Thin wall deep hex sockets, preferred for installing Sun cartridges, are available from Sun or Snap-On Tools Corporation. Complete cavity machining dimensions are provided with form tools or supplied upon request. Dimensions shown below are simplified for manifold design purposes. © SUN Hydraulics Corporation © SUN Hydraulics Corporation Cavity Diameters to be concentric to threads within .002. Cavity Diameters to be concentric to threads within .002. General Information: Cartridge Cavities and Cavity Tools US Selected Assemblies Catalogue #999-901-192 250 SERIES P Minimum Clearance Distances: * See respective Pilot Stage Cartridge Outline Drawing for Deep Socket and Hex Point clearance centerline dimensions High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-8A 994-008-001 994-008-101 Form Reamer TR-8A 995-008-001 995-008-101 Metric Tap M16x1.5-6H 998-991 998-991-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-006, Snap-On P/N: SIML280 Minimum Clearance Distances: * See respective Pilot Stage Cartridge Outline Drawing for Deep Socket and Hex Point clearance centerline dimensions. High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-9A 994-009-001 994-009-101 Form Reamer TR-9A 995-009-001 995-009-101 Metric Tap M16x1.5-6H 998-991 998-991-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-006, Snap-On P/N: SIML280 Deep Socket* Socket Diameter .453 Manifold Edge Hex Point to *CL CL Deep Socket* Socket Diameter .453 Manifold Edge Hex Point to *CL CL Minimum Full Thread Bottom Tap Required 0.000 Locating Shoulder0.000 .391 .531 .141 .438 Port 3 Centerline .188 Maximum .875 .812 Port 2 Centerline .125 Maximum Cartridge Nose Support (.031 minimum below surface) .861 Minimum Hex Extension 1.250 Socket Wrench Clearance (not included on Form Drill) .656 .657 .437 .439 .500 .502 .570 .574 .703 .705 1.095 1.100 1.000 .219 Maximum L.S. Depth without Socket Clearance .136 M16 x 1.5-6H 60o .250 Maximum Port 1 Cartridge Nose Support 0.000 Locating Shoulder .703 .705 0.000 .570 .574 .437 .439 .391 Minimum Full Thread Bottom Tap Required .531 .141 .656 .657 .861 Minimum Hex Extension .438 Port 2 Centerline .188 Maximum (.031 minimum below surface) 1.250 Socket Wrench Clearance (not included on Form Drill) .750 .754 1.000 .219 Maximum L.S. Depth without Socket Clearance .136 .250 Maximum M16 x 1.5-6H 60o Port 1 T-8A 2 Port Sun Cavity T-9A 3 Port Sun Cavity NOTES:Thin wall deep hex sockets, preferred for installing Sun cartridges, are available from Sun or Snap-On Tools Corporation. Complete cavity machining dimensions are provided with form tools or supplied upon request. Dimensions shown below are simplified for manifold design purposes. General Information: Cartridge Cavities and Cavity Tools © SUN Hydraulics Corporation © SUN Hydraulics Corporation Cavity Diameters to be concentric to threads within .002. Cavity Diameters to be concentric to threads within .002. 251 US Selected Assemblies Catalogue #999-901-192 SERIES 0 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-162A 994-162-001 994-162-101 Form Reamer TR-162A 995-162-001 995-162-101 Metric Tap M16x1.5-6H 998-991 998-991-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 3/4” Hex Deep Socket: Sun P/N: 998-100-005, Snap-On P/N: S241 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-163A 994-163-001 994-163-101 Form Reamer TR-163A 995-163-001 995-163-101 Metric Tap M16x1.5-6H 998-991 998-991-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 3/4” Hex Deep Socket: Sun P/N: 998-100-005, Snap-On P/N: S241 .969 Deep Socket Socket Diameter .453 Manifold Edge CL CLHex Point to.875 .969 Deep Socket Socket Diameter .484 Manifold Edge .875 CL CLHex Point to 1.297 0.000 Minimum Depth of .406 for Working Parts Clearance (included on Form Drill) .641 Port 2 Centerline 1.125 Socket Wrench Clearance .696 .609 Minimum Surface from L.S. .906 1.188 Minimum Hex Extension o .188 Port 3 Centerline .312 Maximum 0.000 Locating Shoulder 30 .515 .517 .936 .940 .703 .705 .656 .657 .570 .574 o .156 .531 .908 .406 .531 Maximum 1.219 Cartridge Nose Support Maximum 1 Port 45 (2) Places 25o 1.222 M16x1.5-6H Minimum Full Thread Maximum .656 .657 .570 .574 .156 .531 Minimum Full Thread 45 (2) Places o .908 Cartridge Nose Support .531 Maximum 0.000 Locating Shoulder 1.125 Socket Wrench Clearance .812 Minimum Hex Extension 25o .484 .273 1.219 1.222 M16x1.5-6H .406 1 Port .641 Port 2 Centerline 0.000 1.297 Minimum Depth of .406 for Working Parts Clearance (included on Form Drill) (.031 minimum below surface) .936 .940 .705 .703 .515 .517 T-162A 2 Port Sun Cavity T-163A 3 Port Sun Cavity NOTES:Thin wall deep hex sockets, preferred for installing Sun cartridges, are available from Sun or Snap-On Tools Corporation. Complete cavity machining dimensions are provided with form tools or supplied upon request. Dimensions shown below are simplified for manifold design purposes. © SUN Hydraulics Corporation © SUN Hydraulics Corporation Cavity Diameters to be concentric to threads within .002. Cavity Diameters to be concentric to threads within .002. General Information: Cartridge Cavities and Cavity Tools US Selected Assemblies Catalogue #999-901-192 252 SERIES 1 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-10A 994-010-001 994-010-101 Form Reamer TR-10A 995-010-001 995-010-101 Metric Tap M20x1.5-6H 998-998 998-998-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-001, Snap-On P/N: S281 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-13A 994-013-001 994-013-101 Form Reamer TR-13A 995-013-001 995-013-101 Metric Tap M20x1.5-6H 998-998 998-998-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-001, Snap-On P/N: S281 1.125 Deep Socket Socket Diameter .562 Manifold Edge CL CLHex Point to1.062 .562 Manifold Edge 1.125 Deep Socket Socket Diameter CL CLHex Point to1.062 Cartridge Nose Support .812 Port 2 Centerline .875 Maximum 0.000 Locating Shoulder .688 Minimum Hex Extension 1.250 Socket Wrench Clearance Maximum .531 .734 1.000 .689 .730 .687 .812 .227 45 (3) Places o .814 1.266 1.567 1.572 .156 .859 .861 .500 M20x1.5-6H Minimum Full Thread (not included on Form Drill) (.031 minimum below surface) .438 Maximum L.S. Depth without Socket Clearance Minimum Depth of .531 for Working Parts Clearance Port 1 0.000 1.810 .998 1.002 .227 .859 .861 1.078 .687 .689 .812 .814 .730 .734 1.380 1.385 .156 .500 Minimum Full Thread M20x1.5-6H .531 Maximum 0.000 Locating Shoulder 1.250 Socket Wrench Clearance .719 Port 2 Centerline .688 Maximum .688 Minimum Hex Extension (not included on Form Drill) (.031 minimum below surface) Cartridge Nose Support 1 Port 45 (3) Places o .438 Maximum L.S. Depth without Socket Clearance Minimum Depth of .531 for Working Parts Clearance 0.000 1.59 T-10A 2 Port Sun Cavity T-13A 2 Port Sun Cavity NOTES:Thin wall deep hex sockets, preferred for installing Sun cartridges, are available from Sun or Snap-On Tools Corporation. Complete cavity machining dimensions are provided with form tools or supplied upon request. Dimensions shown below are simplified for manifold design purposes. General Information: Cartridge Cavities and Cavity Tools © SUN Hydraulics Corporation © SUN Hydraulics Corporation Cavity Diameters to be concentric to threads within .002. Cavity Diameters to be concentric to threads within .002. 253 US Selected Assemblies Catalogue #999-901-192 SERIES 1 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-11A 994-011-001 994-011-101 Form Reamer TR-11A 995-011-001 995-011-101 Metric Tap M20x1.5-6H 998-998 998-998-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-001, Snap-On P/N: S281 Minimum Clearance Distances: High Speed Steel Titanium Coated Description Model Code Model Code Form Drill TD-21A 994-021-001 994-021-101 Form Reamer TR-21A 995-021-001 995-021-101 Metric Tap M20x1.5-6H 998-998 998-998-101 Note: Drill and Reamer have a #3 Morse taper. Tap has straight shank. 7/8” Hex Deep Socket: Sun P/N: 998-100-001, Snap-On P/N: S281 1.125 Deep Socket Socket Diameter .594 Manifold Edge CL CLHex Point to1.062 1.125 Deep Socket Socket Diameter .625 Manifold Edge 1.062 CL CLHex Point to 1 Port 1.781 Minimum Hex Extension 1.250 Socket Wrench Clearance .250 Maximum .312 Maximum .688 Maximum Cartridge Nose Support 1.188 Minimum Surface from L.S. .188 Port 3 Centerline 0.000 Locating Shoulder .719 Port 2 Cen