Usage:
Start By:
a. remove main hydraulic pump and pump drive coupling
NOTE: The main hydraulic pump is made up of a front pump, port block and a rear pump. Steps 4 through 36 are for the disassembly procedure for the front pump assembly. Disassembly of the rear pump assembly is identical to the front pump assembly with the exception of Steps 40 and 41.
1. Be sure the outside of the main hydraulic pump is thoroughly clean prior to disassembly. Remove the two drain plugs from the bottom of the hydraulic oil pumps. Drain the hydraulic oil from both pumps into a suitable container, and reinstall the drain plugs.
2. Put an alignment mark across the pump bodies and port block for assembly purposes.
3. Remove the pilot pump from the main hydraulic pump.
4. Loosen four nuts (1) in the sequence shown. Do not remove the nuts completely at this time.
5. Install tool (A) on the hydraulic oil pump as shown. Fasten a hoist to the pump, and put it in a vertical position. The weight of the pump is approximately 181 kg (400 lb). Remove nuts (1).
6. Remove the front pump assembly (without the piston and barrel assembly) from the port block and rear pump assembly. The weight of front pump (2) is approximately 54 kg (120 lb).
| NOTICE |
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During removal of the piston and barrel assembly, do not let the components fall apart. All parts of the two assemblies must be reinstalled in their original locations. |
7. Remove plate (3), piston assembly (4), barrel assembly (5), retainer (6), plate (7) and front plate (8) as a unit. Do not separate the components at this time.
8. Remove plate (3) from the piston assembly.
| NOTICE |
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Prior to removal of piston assembly (4) from the barrel assembly, put identification marks on piston shoe assemblies (10) as to their location in retainer (9) and barrel assembly (5). The piston shoe assemblies must be installed in their original bores in the retainer and barrel assembly. |
9. Remove piston assembly (4) from the barrel assembly. Separate piston shoe assemblies (10) from retainer (9).
10. Remove retainer (11) and spacer (12) from barrel assembly (5).
NOTE: Prior to removal, put identification marks on the bushings (13) as to their location in the barrel. Also, seals (15) and springs (14) must be installed in their original bores in retainer (6) and the barrel. Put identification marks on these components for assembly purposes.
11. Remove barrel assembly (5). Remove bushings (13) from the barrel.
12. Separate front plate (8) and plate (7) from retainer (6). Remove springs (14) and seals (15) from the retainer.
13. Remove retaining ring (16).
14. Install two 6V5221 Bolts (17), which are part of tooling (B), in case (18).
15. With tooling (B) installed as shown, remove case (18) from the front pump body.
16. Remove O-ring seal (20) and lip-type seal (19) from the case.
17. Use a soft faced hammer to remove front shaft (21) from the front pump body. Remove the shaft in the direction shown.
18. Remove retaining ring (22) that positions bearing (23) on front shaft (21).
19. Put front shaft (21) in a press as shown. Press the shaft out of bearing (23).
20. Put identification marks on covers (24) and (25) as to their location on the front pump body. Remove covers (24) and (25) from the front pump body. If necessary, remove the setscrew and nut from each cover.
21. Install a suitable size screw in stopper (27). Remove the stopper from the front pump body.
22. Put an identification mark on cover (26) as to its location on the front pump body. Remove cover (26) from the pump body.
Typical Example
23. Remove retainer (31), two springs (30), guide (29) and ball (28) from the pump body. Remove O-ring seal (33) from the retainer. Remove nut (34) and setscrew (32) from cover (26). Remove the shims from cover (26).
24. Install a suitable size screw in stopper (35). Remove the stopper from the pump body.
25. Put an identification mark on cover (36) as to its location on the front pump body. Remove cover (36) from the pump body.
26. Remove O-ring seal (40) from cover (36). Remove piston (43), spring (42), piston (41), spring (39), shims (38) and spool (37) from the pump body.
27. Remove O-ring seal (44) and back-up ring (45) from stoppers (27) and (35).
28. Remove the cotter pin, nut (47) and spacer (46) from the end of retainer (49).
29. Remove retainer (49) and front link (48) from the pump body. If necessary, remove the plate and rollers from the front link.
30. Remove O-ring seal (50) from retainer (49).
31. Remove sleeve (51) from the front pump body.
32. Put an identification mark on shaft (52) as to its location in the front pump body. Remove shaft (52) from the pump body with a soft faced hammer.
33. Remove O-ring seal (53) from shaft (52).
34. Put an identification mark on shaft (55) as to its location in the front pump body. Remove shaft (55) from the front pump body with a soft faced hammer. Remove the O-ring seal from shaft (55).
35. Remove piston (54) and swashplate (56) from the front pump body.
36. Remove guide block (59) from the swashplate. Use a hammer and punch to remove two bushings (60). Remove roller (57) and dowel pin (58) from the swashplate.
NOTE: The following steps are for the removal and disassembly of the port block.
37. Remove four nuts (61) and the lockwashers; then separate port block (62) from the rear pump assembly.
38. Remove two O-ring seals (65) from the port block.
39. Remove two bearings (63) and splined coupling (64) from the port block. Use a hammer and a brass punch to remove each bearing. Tap against the end of the splined coupling to remove each bearing.
NOTE: The following steps are for the disassembly of the rear pump assembly.
40. Remove the four socket head bolts that hold cover (66) to the rear pump body. Reinstall two of the socket head bolts in the forcing screw holes in cover (66) as shown. Tighten the bolts evenly to loosen the cover. Remove the cover.
41. Remove O-ring seal (67) from cover (66).
NOTE: The disassembly procedure for the remainder of the rear pump assembly is identical to the front pump assembly.
42. Follow Steps 7 through 36 for completing the disassembly of the rear pump assembly.
NOTE: The following steps are for assembly of the main hydraulic pump.
43. Be sure all parts for the front pump assembly, the port block and the rear pump assembly are thoroughly clean and free of dirt and debris prior to reassembly. Check the condition of all parts in the main hydraulic pump. Guideline For Reusable Parts "Piston Pumps And Motors", Form No. SEBF8032-01 can be used as a guide for reconditioning and determining the reusability of parts.
NOTE: Steps 44 through 88 are for reassembly of the front pump.
44. Install dowel pin (58) in swashplate (56). Install the dowel pin in its original position.
45. Install roller (57) in swashplate (56). Install the roller in its original position. There is no chamfer on the roller. It can be installed either way.
46. Install two bushings (60) in swashplate (56) with a press. Install the bushings with the notch in the position shown in Illustration C28571P1.
47. Put a thin coat of 1U6396 Assembly Compound on the surface of plate (3) that makes contact with swashplate (56). Install plate (3) in swashplate (56). Be sure the plate is tight against the swashplate. Check the clearance between the plate and the swashplate with a feeler gauge. See the Specifications module for the correct clearance.
48. Install swashplate (56) in the front pump body. Be sure it is positioned correctly.
| NOTICE |
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The hole in guide block (59) is not in the center. Be sure the guide block is installed correctly on the roller. |
49. Install guide block (59) on the roller of swashplate (56).
50. Put clean hydraulic oil on piston (54). Install the piston into the front pump body. Be sure guide block (59) is in position in piston (54) as shown in the illustration.
51. Check the condition of the O-ring seals used on shafts (52) and (55). If the seals are worn or damaged, use new parts for replacement. Install the O-ring seals on the shafts.
52. Install shafts (52) and (55) in their original locations in the front pump body and swashplate with a soft faced hammer. Install the four socket head bolts that hold each shaft. Tighten the bolts to a torque of 44 ± 1 N·m (32 ± 1 lb ft).
53. Move the swashplate back and forth. It should move smoothly.
54. Put clean hydraulic oil on spool (37). Install the spool in sleeve (51) as shown in the illustration. Be sure the spool slides smoothly in the bore of the sleeve.
55. Install the spool and sleeve in the front pump body.
56. If the roller was removed from front link (48), reinstall it in its original position on the front link. Reinstall the plate on the roller.
57. Install the front link in the front pump body. Slide the plate on the front link into the concave area of sleeve (51). Align the concave area of the front link with roller (57) in the swashplate.
58. Check the condition of O-ring seal (50) for retainer (49). If the seal is worn or damaged, use new parts for replacement. Install the O-ring seal on the retainer. Install retainer (49) in the front pump body. Tighten the retainer to a torque of 72 ± 1 N·m (51 ± 1 lb ft). Install spacer (46), nut (47) and the cotter pin.
59. Check the condition of O-ring seals (44) and back-up rings (45) used on stoppers (27) and (35). If the rings and seals are worn or damaged, use new parts for replacement. Install the back-up rings and O-rings seals on stoppers (27) and (35).
60. Put clean hydraulic oil on the O-ring seals and back-up rings on stoppers (27) and (35). Install the stoppers in the front pump body.
NOTE: After assembly and installation of the main hydraulic pump, see the Testing And Adjusting module to accurately adjust the setscrews in covers (24) and (25).
61. If the setscrew and nut were removed from covers (24) and (25), reinstall the components. Tighten the nut to a torque of 177 ± 1 N·m (131 ± 1 lb ft).
62. Install covers (24) and (25) in their original locations on the front pump body. Tighten the socket head bolts that hold the covers to a torque of 72 ± 1 N·m (51 ± 1 lb ft).
63. Put clean hydraulic oil on piston (41). Install piston (41) in piston (43). Be sure piston (41) slides smoothly in the bore of piston (43).
64. Install spring (39) over piston (43). Install the original amount of shims (38) against spring (39). Install spring (42) on piston (43).
65. Put clean hydraulic oil on piston (43). Install the piston, springs and shims in the front pump body as a unit. Be sure the piston slides smoothly in the bore in the pump body.
66. Check the condition of O-ring seal (40) used on cover (36). If the seal is worn or damaged, use new parts for replacement. Install the O-ring seal on cover (36). Install cover (36) and the two socket head bolts which hold it. Tighten the bolts to a torque of 44 ± 1 N·m (31 ± 1 lb ft).
67. Install two spring (30) on guide (29). Apply 1U6396 Assembly Compound in the concave seat in the end of the guide. Install ball (28) in the seat.
68. Install the guide, springs and ball in the front pump body as a unit. Be sure the ball does not fall out of the seat during installation.
69. Check the condition of the O-ring seal used on retainer (31). If the seal is worn or damaged, use new parts for replacement. Install the O-ring seal on the retainer. Put clean hydraulic oil on the O-ring seal, and install the retainer in cover (26).
70. Install nut (34) and setscrew (32) in cover (26). Tighten nut (34) to a torque of 16 ± 1 N·m (12 ± 1 lb ft). Final adjustment of the setscrew will be made after assembly and installation of the main hydraulic pump. See the Testing And Adjusting module.
71. Install retainer (31) the shims and cover (26) in the front pump body. Install the two socket head bolts that hold the cover. Tighten the bolts to a torque of 44 ± 1 N·m (31 ± 1 lb ft).
72. If the four studs used to hold the front pump to the port block were removed, reinstall them in the pump body. Install the studs with the chamfered side of the stud in the pump body. Tighten the studs to a torque of 177 ± 1 N·m (131 ± 1 lb ft). After tightening, the studs should protrude from the pump body 46.00 ± 1.00 mm (1.811 ± 0.040 in).
| NOTICE |
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To prevent damage to bearing (23), support the inner race of the bearing during installation of front shaft (21) in the bearing. |
73. Use a press to install front shaft (21) in bearing (23). Install the shaft until the shoulder on the shaft comes in contact with the bearing. Install retaining ring (22) which retains bearing (23).
74. Install front shaft (21) and the bearing in the front pump body.
75. Put a thin coat of 5P3413 Sealant on surfaces (X) of case (18). Install lip-type seal (19) in case (18) with the lip of the seal facing in as shown. Be sure the seals make contact with the counterbore in the case during installation.
76. Check the condition of O-ring seal (20) used on case (18). If the seal is worn or damaged, use new parts for replacement. Install O-ring seal (20) on case (18).
77. Put clean hydraulic oil on the lip of seal (19) and on O-ring seal (20). Install case (18) in the front pump body with a soft faced hammer. Be sure the case is tight against the counterbore in the front pump body.
78. Install retaining ring (16) which holds case (18) in the front pump body. During installation of the ring, be sure the separation in the ring is in alignment with the removal hole in the case as shown in Illustration C28577P1.
79. Install piston shoe assemblies (10) in their original bores in retainer (9).
80. Put clean hydraulic oil on the outside surface of retainer (11). Install spacer (12) and retainer (11) in the barrel. Put clean hydraulic oil on bushings (13). Install the bushings in their original bores in the barrel.
81. Put clean hydraulic oil on the outside of piston shoe assemblies (10). Install piston assembly (4) in the barrel. Be sure the piston shoe assemblies are installed in their original bores in the barrel.
82. Move the piston assembly in all directions by hand to be sure the piston shoe assemblies move freely in their bores in the barrel.
83. Put clean hydraulic oil on the sliding surface of plate (3), the shoes of the piston shoe assemblies and on the splines of front shaft (21).
NOTE: Proper positioning of the pump body will aid in the installation of the piston assembly and barrel assembly.
84. Put the front pump body in the position shown in the Illustration C28578P1. Support the rear of the body to hold it at a slight angle. Carefully install the piston assembly and barrel assembly on the front shaft so the unit does not come apart. Be sure the barrel assembly rotates by hand. Also, visually check the retainer for the piston shoe assemblies to be sure it moves smoothly.
85. Put the front pump body in a vertical position. Use wood blocks to hold the body in position.
86. Install springs (14) in their original bores in the barrel assembly. Install seal retainer plate (6) over the springs as shown in Illustration C28579P1.
87. Put clean hydraulic oil on seals (15). Install the seals in their original bores in the seal retainer plate. Rotate each seal to be sure it moves smoothly in the bore of seal retainer plate (6).
88. Put clean hydraulic oil on the sealing surface of each seal (15) and on the sealing surface of valve plate (7). Install valve plate (7) in its original position on front shaft (21). Push down on valve plate (7) by hand to be sure the spring force returns the plate smoothly. Put clean hydraulic oil on the sliding surface of valve plate (7).
NOTE: The following steps are for assembly of the port block.
89. Install one bearing (63) in the port block with a press. Turn the port block over. Install splined coupling (64). Press the other bearing (63) in the port block.
90. Check the condition of O-ring seals (65) used on the port block. If the seals are worn or damaged, use new parts for replacement. Install O-ring seals (65) on the port block.
NOTE: The following steps are for assembly of the rear pump. Assembly of the rear pump is identical to the front pump with the exception of Steps 92 and 93.
91. Follow Steps 45 through 89 for partial assembly of the rear pump.
92. Check the condition of O-ring seal (67) for cover (66). If the seal is worn or damaged, use new parts for replacement. Install O-ring seal (67) on cover (66).
93. Put clean hydraulic oil on O-ring seal (67), and install cover (66) on the rear pump body. Install the four socket head bolts that hold cover (66), and tighten them to a torque of 44 ± 1 N·m (31 ± 1 lb ft).
NOTE: The following steps are for connection of the rear pump, port block and front pump.
94. Put the rear pump assembly in a vertical position with the splined shaft up.
| NOTICE |
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The cocoon-shaped port in the rear plate of the rear pump assembly and the front plate of the front pump assembly must be in alignment with each other during connection of the pump assemblies. Also, the ports must line up with the centerline of a gear tooth on the front and rear shaft in each pump assembly and the splined coupling in the port block. The front and rear links must also be in alignment with the ports in each plate and the centerline of the gear tooth in both pump assemblies and the port block. Refer to Illustration C28580P1 for the correct alignment of the components. |
95. Put alignment marks on the cocoon-shaped port in the rear plate of the rear pump and the front plate of the front pump. Also, mark the centerline of a gear tooth on the shaft in the rear and front pumps and the splined coupling in the port block.
96. Put clean hydraulic oil on the O-ring seals on the port block. Install the port block on the rear pump.
Be sure the alignment marks on the outside of the pump body and the port block line up with each other. Also, be sure the alignment marks for the cocoon-shaped port in the rear plate, the rear link and the centerline of the gear teeth are in alignment as shown in the illustration. Install the four washers and nuts that hold the port block to the rear pump. Temporarily tighten the nuts.
97. Put the rear pump and port block in a horizontal position. Fasten a hoist to the front pump, and put it in position on the port block. Again, be sure the alignment marks for the cocoon-shaped port in the front plate, the front link and the centerline of the gear teeth are in alignment with the marks in the port block and rear pump. Install the four washers and nuts that hold the front pump to the port block. Temporarily tighten the nuts.
98. Tighten the nuts that hold the front and rear pumps to the port block. Tighten the nuts in the number sequence shown in Illustration C28581P1 to a torque of 177 ± 1 N·m (131 ± 1 lb ft).
99. Install the pilot oil pump on the main hydraulic pump. Tighten the two bolts that hold the pilot pump to the main hydraulic pump to a torque of 44 ± 1 N·m (31 ± 1 lb ft).
| NOTICE |
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To prevent damage to the main hydraulic pump, fill the pump with clean hydraulic oil up to the level of the fill port prior to operation. |
End By:
a. install main hydraulic pump and pump drive coupling