Usage:
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is stopped and when the fill plug is cool enough to touch with your bare hands. |
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NOTE: Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the hydraulic system.
1. Connect a hose to valve (1). Drain hydraulic tank (2). The capacity of the hydraulic tank is 117.5 liters (31 gallons).
2. Disconnect hose (4). Cap or plug immediately.
3. Disconnect hose (5). Cap or plug immediately.
4. Disconnect hose (11). Cap or plug immediately.
5. Disconnect hoses (10). Cap or plug immediately.
6. Disconnect hose (8). Cap or plug immediately.
7. Disconnect hose (9). Cap or plug immediately.
8. Remove bolt (7) and P-clamp.
9. Disconnect electrical connection (12).
10. Attach a strap and a suitable lifting device to vibratory pump (13).
11. Remove bolt (14) (not shown).
13. Remove two bolts (6) (not shown).
14. Remove two bolts (3).
15. Remove vibratory pump (13) and adapter from the engine. The weight of the vibratory pump is approximately 44 kg (97 lb).
NOTE: For installation of the vibratory pump, reverse the removal steps.
16. Fill the hydraulic tank to the correct level. Refer to the Operation & Maintenance Manual KEBU6665 for the correct level.
Disassemble & Assemble Vibratory Pump
Start By:
a. remove vibratory pump
1. Thoroughly clean the outside of the vibratory pump prior to disassembling it.
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The drive gear for the vibratory pump is a press fit on the tapered end of the pump shaft. The drive gear will come off the tapered end of the pump shaft with force when it is loosened with Tool (A). To prevent possible personal injury during removal of the drive gear, only loosen retaining nut (1). Do not remove it from the pump shaft. The nut will retain the components on the pump shaft when they are loosened from the tapered end of the pump shaft with Tool (A). |
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2. Loosen retaining nut (1), but do not remove it from the pump shaft. Retaining nut (1) will retain the drive gear for the vibratory pump when it is loosened from the tapered end of the pump shaft with Tool (A).
3. Remove two bolts (2) that hold front cover (3) to the pump housing.
4. Locate retaining nut (1) on the end of the pump shaft as shown. Install Tool (A) on the cover plate. Loosen drive gear (4) from the tapered end of the pump shaft with Tool (A).
5. Remove Tool (A), retaining nut (1), drive gear (4) and cover plate (3) from the pump.
6. Remove bypass valve (5) from the pump housing. Remove back-up ring (6) and O-ring seal (7) from the bypass valve.
NOTE: Do not disassemble poppet (10). This assembly is preset at the factory.
7. Remove charge check and relief valve (8) from the pump housing. Remove plug (13), spring (11) and poppet (10). Remove O-ring seal (12) from plug (13).
8. Remove charge relief valve (9) from the pump housing. Remove plug (18), shims (16), spring (15) and relief valve (14). Remove O-ring seal (17) from plug (18).
9. Remove O-ring seal (19) from adapter (20). Remove three bolts (21) and adapter (20) from the pump housing.
10. Remove load ring (24) from cover (22). Remove O-ring seal (23) from the pump housing.
11. Remove three bolts (25) and filter adapter (26) from the pump housing.
12. Remove three O-ring seals (27) and two plugs (28) from filter adapter (26).
13. Mark the position of the manual displacement control lever in relation to the pump housing for installation purposes.
14. Remove bolt (29), and pull manual displacement control lever (30) out of the sleeve in the pump housing.
15. Remove locknut (31) and the lockwasher from the of end of spool (34). Remove the spool from the control lever. Separate handle (37), bracket (36) and spring (35). Remove O-ring seal (33) and back-up ring (32) from the spool.
16. Remove control sleeve (40) from the pump housing. Remove O-ring seal (38) and back-up ring (39) from the control sleeve.
17. Remove O-ring seal (42) from the front cover assembly.
18. Remove seven bolts (41) that hold the front cover assembly to the pump housing. Remove front cover assembly (43).
19. Remove two journal bearings (44) and two pins (45) from the front cover.
20. Remove snap ring (46) with Tool (B).
21. Remove seal (47) from the front cover with Tool (C).
22. Remove snap ring (48) from the front cover with Tool (B). Remove the shaft and bearing, as a unit, from the front cover with a soft faced hammer.
23. Using Tool (D), remove snap ring (49) that holds bearing (50) in position on shaft (51).
24. Using a press, remove shaft (51) from bearing (50).
25. Remove remaining snap ring (52) from shaft (51) with Tool (D).
26. Remove swashplate (53) from the pump housing.
27. Disassemble the swashplate. Remove sleeve bearing (54) and pins (55) and (56) from the swashplate.
| NOTICE |
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During removal of the cylinder block assembly from the pump housing, do not let the components fall apart. The piston assemblies should be reinstalled in their original bores in the guide and the cylinder block. |
28. Remove cylinder block assembly (57) from the pump housing with Tool (E).
29. Put identification marks on seven piston assemblies (58) as to their location in guide (59) and cylinder block (60). Remove piston assemblies (58) from guide (59) and cylinder block (60).
30. Remove retainer (61) from the cylinder block.
31. Remove pin retainer (62) and three pins (63) from the cylinder block.
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There is spring force against washer (64). When retaining ring (66) is removed, the spring force will be released. To prevent possible personal injury, removal of the internal components in cylinder block (60) should be performed in a press in order to retain spring (65) and washer (64). |
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32. Put cylinder block (60) in a press. Install a suitable piece of square steel stock against washer (64). Put slight compression on washer (64) with the press. Remove retaining ring (66), and slowly release the spring compression.
| NOTICE |
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Washers (64) and (67) are different in size. Put identification marks on the washers so they can be installed in their original location in the cylinder block. |
33. Remove washer (64), spring (65) and washer (67) from the cylinder block.
| NOTICE |
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During removal, do not damage valve plate (70). |
34. Put an identification mark on valve plate (70) as to its position in the pump housing. Remove valve plate (70) with Tool (G). If necessary, remove locating pin (68).
35. Remove needle bearing (69) from the pump housing.
36. Remove five bolts (71). Remove cover (72) and the servo piston as a unit. Remove the gasket from the cover.
37. Remove locknut (74) and servo piston (73) from cover (72).
38. Remove two piston rings (75) and two bearing rings (76) from the servo piston.
NOTE: The following steps are for the assembly of the vibratory pump.
39. Be sure all parts of the vibratory pump are clean and free of dirt and debris prior to assembly.
| NOTICE |
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Most of the components in the vibratory pump have critical, high tolerance surfaces. Do not damage these surfaces during assembly of the pump. Protect all exposed surfaces, openings and ports from damage and foreign material. Lubricate all surfaces of the pump with clean hydraulic oil prior to assembly. |
40. Check the condition of two piston rings (75) and two bearing rings (76). If the rings are worn or damaged, use new parts for replacement.
41. Put a thin coat of 1U6396 Assembly Compound on two piston rings (75) and two bearing rings (76). Install the piston rings and bearing rings on the servo piston in the position shown.
42. Install servo piston (73) in cover (72). Install locknut (74) that holds the unit together. Tighten locknut (74) to a torque of 17 to 25 N·m (13 to 18 lb ft).
43. Install a new gasket on cover (72). Install the servo piston and cover (72) in the pump housing. Install five bolts (71) that hold it. Tighten the bolts to a torque of 13.6 to 17.6 N·m (10 to 13 lb ft).
NOTE: Refer to the Testing & Adjusting module for the correct neutral position adjustment of the pump servo.
44. Install needle bearing (69) in the pump housing with a press. Install the bearing until it makes contact with the counterbore in the pump housing and with the printed number on the bearing facing up.
45. Install locating pins (68) in the pump housing. Put clean hydraulic oil on valve plate (70). Install valve plate (70) in its original position in the pump housing. Ensure the cutouts and bevels in the plate are facing up, and the plate is engaged with locating pins (68).
46. Install washer (67), spring (65) and washer (64) in the cylinder block. Put the cylinder block in a press. Install a suitable piece of square steel stock against washer (64). Using a press, compress spring (65), and install retaining ring (66). Slowly release the spring compression.
47. Install three pins (63) in the cylinder block. Install pin retainer (62) on the cylinder block.
48. Install retainer (61) in the cylinder block.
49. Put clean hydraulic oil on seven piston assemblies (58). Install the piston assemblies in their original bores in guide (59). Install the guide with the piston assemblies in their original bores in cylinder block (60).
50. Using Tool (E), install cylinder block assembly (57) in the pump housing.
51. Assemble the swashplate. Install pins (56) and (55) in the swashplate. Install sleeve bearing (54).
52. Install swashplate (53) in the pump housing as shown.
53. Install snap ring (52) on shaft (51) with Tool (D).
54. Press shaft (51) into bearing (50) until the bearing makes contact with snap ring (52). Install snap ring (49) with Tool (D).
55. Install shaft (51) and the bearing in the front cover with a soft faced hammer. Install snap ring (48) with Tool (B).
56. Put clean grease on the inside diameter of seal (47). Install the seal in the front cover with Tool (F). Install the seal until it is approximately 9.40 mm (.370 in) below the outside surface of the front cover.
57. Install snap ring (46) in the front cover with Tool (B).
58. Install two pins (45) and two journal bearings (44) in the front cover.
59. Align the bore in cylinder block assembly (57), the retainer and needle bearing (69) prior to installation of front cover assembly (43) in the pump housing. Install front cover assembly (43) in the pump housing. Install seven bolts (41) that hold it.
60. Check the condition of O-ring seal (42). If the seal is worn or damaged, use a new part for replacement. Put 1U6396 Assembly Compound on O-ring seal (42). Install the O-ring seal on the front cover assembly.
61. Check the condition of O-ring seal (38) and back-up ring (39). If the seal or ring is worn or damaged, use new parts for replacement. Install back-up ring (39) and O-ring seal (38) on control sleeve (40). Put 1U6396 Assembly Compound on the back-up ring and O-ring seal.
62. Be sure the orifice in control sleeve (40) is clean prior to installation in the pump housing. Align the slot in control sleeve (40) with the swashplate feedback pin. Install the control sleeve in the pump housing.
63. Assemble manual displacement control lever (30) as follows:
a. Check the condition of O-ring seal (33) and back-up ring (32). If the seal or ring is worn or damaged, use new parts for replacement. Install the O-ring seal (33) and back-up ring (32) on spool (34) as shown.
b. Install spring (35), bracket (36) and handle (37) on spool (34). Install the lockwasher and locknut (31)
64. Put 1U6396 Assembly Compound on spool (34). Put manual displacement control lever (30) in its original position in the pump housing. Install bolt (29) that holds it.
65. Check the condition of O-ring seals (27). If the seals are worn or damaged, use new parts for replacement.
66. Put 1U6396 Assembly Compound on O-ring seals (27). Install O-ring seals (27) and two plugs (28) in filter adapter (26).
67. Put filter adapter (26) in position on the pump housing. Install three bolts (25) that hold it. Tighten bolts (25) to a torque of 25 ± 3 N·m (18 ± 2 lb ft).
68. Install load ring (24) in cover (22).
69. Check the condition of O-ring seal (23). If the seal is worn or damaged, use a new part for replacement. Install O-ring seal (23) on the pump housing.
70. Put adapter (20) in position in the pump housing. Install three bolts (21) that hold it.
71. Check the condition of O-ring seal (19). If the seal is worn or damaged, use a new part for replacement. Install the O-ring seal in adapter (20).
72. Check the condition of back-up ring (6) and O-ring seal (7). If the seal or ring are worn or damaged, use new parts for replacement. Install the back-up ring and O-ring seal on bypass valve (5) as shown. Put 1U6396 Assembly Compound on the O-ring seal and the back-up ring on the bypass valve. Install the bypass valve in the pump housing.
73. Install charge relief valve (9) as follows:
a. Put clean hydraulic oil on all parts of the charge relief valve.
b. Check the condition of O-ring seal (17). If the seal is worn or damaged, use a new part for replacement. Install the O-ring seal on plug (18).
c. Install relief valve (14), spring (15), shims (16) and plug (18) in the pump housing. Tighten the plug to a torque of 70 ± 27 N·m (50 ± 20 lb ft).
74. Install charge check and relief valve (8) as follows:
a. Put clean hydraulic oil on all part of the charge check and relief valve.
b. Check the condition of O-ring seal (12). If the seal is worn or damaged, use a new part for replacement. Install the O-ring seal on plug (13).
c. Install poppet (10), spring (11) and plug (13) in the pump housing. Tighten the plug to a torque of 183 ± 47 N·m (135 ± 35 lb ft).
75. Put cover plate (3) in its original position on the pump housing. Install two bolts (2) that hold it.
76. Put drive gear (4) in position on the pump shaft. Install retaining nut (1) that holds the gear in place. Tighten the retaining nut to a torque of 170 ± 20 N·m (125 ± 15 lb ft).
End By:
a. install vibratory pump