GROUP 3 PUMP DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
(3) Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious injury.
23
(4) Remove the wirings for the pressure 8
sensors and so on. A2
A1

(5) Loosen the drain plug under the hydraulic

tank and drain the oil from the hydraulic 7
tank.
Hydraulic tank quantity : 160
(6) Remove socket bolts (23) and disconnect
pipe (7, 8). 24
1
(7) Disconnect pilot line hoses (2, 3, 4, 5, 6,
7).
2209S8MP01

(8) Remove socket bolts(24) and disconnect

pump suction tube (1).
When pump suction tube is disconnected,
the oil inside the piping will flow out, so 3 4
catch it in oil pan. 2 5

(9) Sling the pump assembly and remove the

Dr
A3
pump mounting bolts. Psv
Pi1
Weight : 140 kg (310 lb)
Pull out the pump assembly from housing.
B3
When removing the pump assembly,
check that all the hoses have been Pi2

disconnected. 6
7
2209S8MP02

8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
Remove the air vent plug (2EA).
Tighten plug lightly.
Start the engine, run at low idling, and
check oil come out from plug.
Tighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-8
 2. MAIN PUMP (1/2)
The main pump consists of two piston pumps (front & rear) and valve block.

535 789 732 532 214 548 531 724 702 792 534 808 901 954 717 151 152 211 113
953 A
806
886
717
406
261 04

774
111

127
123
710
824
251 490 212 153 156 468 157
728 313 124 312 114 885 314 141 271 401
466
725

2209S2MP02

04 Gear pump 261 Seal cover (F) 717 O-ring

111 Drive shaft (F) 271 Pump casing 724 O-ring
113 Drive shaft (R) 312 Valve block 725 O-ring
114 Spline coupling 313 Valve plate (R) 728 O-ring
123 Roller bearing 314 Valve plate (L) 732 O-ring
124 Needle bearing 401 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 406 Hexagon socket bolt 789 Back up ring
141 Cylinder block 466 VP Plug 792 Back up ring
151 Piston 468 VP Plug 806 Hexagon head nut
152 Shoe 490 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Support 710 O-ring

8-9
 MAIN PUMP (2/2)

544

543
545
541

079

VIEW A
21092MP08

541 Seat 544 Stopper 2 079 Proportional reducing valve

543 Stopper 1 545 Steel ball

8-10
 2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew

Allen wrench 4 M 5 BP-1/16 - M 8

5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
B
8 M10 BP-3/8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2 -
Double ring spanner, Hexagon socket VP plug
- Hexagon nut
socket wrench, double (single) head bolt (PF thread)
open end spanner 19 M12 M12 VP-1/4
24 M16 M16 -
B
27 M18 M18 VP-1/2
30 M20 M20 -
36 - - VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 108200
Torque wrench Capable of tightening with the specified torques

8-11
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfm lbfft in mm

Hexagon socket head bolt M 5 0.7 5.1 0.16 4

(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug (Material : S45C) PT1/16 0.7 5.1 0.16 4
Wind a seal tape 1 1/2 to PT 1/8 1.05 7.59 0.20 5
2 turns round the plug PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug (Material : S45C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17

8-12
3) DISASSEMBLY
(1) Select place suitable to disassembling.
Select clean place.
Spread rubber sheet, cloth or so on on
overhaul workbench top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove drain port plug (468) and let oil
out of pump casing (front and rear pump).

(4) Remove hexagon socket head bolts (412,

413) and remove regulator.

(210-7) MP01

(5) Loosen hexagon socket head bolts (401)

which tighten swash plate support (251),
pump casing (271) and valve block (312).
If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.

(6) Place pump horizontally on workbench

with its regulator-fitting surface down and
separate pump casing (271) from valve
block (312).
Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.

(210-7) MP02

8-13
(7) Pull cylinder block (141) out of pump
casing (271) straightly over drive shaft
(111). Pull out also pistons (151), set
plate (153), spherical bush (156) and
cylinder springs (157) simultaneously.
Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.

(210-7) MP03

(8) Remove hexagon socket head bolts (406)

and then seal cover (F, 261).
Fit bolt into pulling out tapped hole of seal
cover (F), and cover can be removed
easily.
Since oil seal is fitted on seal cover (F),
take care not to damage it in removing
cover.
(9) Remove hexagon socket head bolts (408) (210-7) MP04

and then seal cover (R, 262).

In case fitting a gear pump, first, remove
gear pump.
(10) Tapping lightly fitting flange section of
swash plate support (251) on its pump
casing side, separate swash plate support
from pump casing.

(210-7) MP05

(11) Remove shoe plate (211)and swash plate

(212) from pump casing (271).

(210-7) MP06

8-14
(12) Tapping lightly shaft ends of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.

(210-7) MP07

(13) Remove valve plates (313, 314) from

valve block (312).
These may be removed in work (6).

(210-7) MP08

(14) If necessary, remove stopper (L, 534),

stopper (S, 535), servo piston (532) and
tilting pin (531) from pump casing (271),
and needle bearing (124) and splined
coupling (114) from valve block (312).
In removing tilting pin, use a protector to
prevent pin head from being damaged.
Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
Do not loosen hexagon nuts of valve
block and swash plate support.
If loosened, flow setting will be changed.

8-15
4) ASSEMBLY
(1) F o r r e a s s e m b l i n g r e v e r s e t h e
disassembling procedures, paying
attention to the following items.
Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
Clean each part fully with cleaning oil
and dry it with compressed air.
Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
In principle, replace seal parts, such as
O-rings, oil seals, etc.
For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.

(2) Fit swash plate support (251) to pump

casing (271), tapping the former lightly
with a hammer.
After servo piston, tilting pin, stopper (L)
and stopper (S) are removed, fit them
soon to pump casing in advance for
reassembling.
In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
(210-7) MP09
and feedback pin from being damaged.
In addition, apply loctite (Medium
strength) to their threaded sections.

8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin (531) and fit swash plate
(212) to swash plate suppor t (251)
correctly.
Confirm with fingers of both hands that
swash plate can be removed smoothly.
Apply grease to sliding sections of swash
plate and swash plate support, and drive
(210-7) MP10
shaft can be fitted easily.

(4) To swash plate support (251), fit drive

shaft (111) set with bearing (123), bearing
spacer (127) and snap ring (824).
Do not tap drive shaft with hammer or so
on.
Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
(210-7) MP11

(5) Assemble seal cover (F, 261) to pump

casing (271) and fix it with hexagon
socket head bolts (406).
Apply grease lightly to oil seal in seal
cover (F).
Assemble oil seal, taking full care not to
damage it.
For tandem type pump, fit rear cover
(263) and seal cover (262) similarly.
(210-7) MP12

(6) Assemble piston cylinder subassembly

c y l i n d e r bl o ck ( 1 4 1 ) , p i s t o n
subassembly (151, 152), set plate (153),
spherical bush (156), spacer (158) and
cylinder spring (157).
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
(210-7) MP13

8-17
(7) Fit valve plate (313) to valve block (312),
entering pin into pin hole.
Take care not to mistake suction / delivery
directions of valve plate.

(210-7) MP14

(8) Fit valve block (312) to pump casing (271)

and tighten hexagon socket head bolts
(401).
At first assemble this at rear pump side,
and this work will be easy.
Take care not to mistake direction of valve
block.
Clockwise rotation (Viewed from input
shaft side) - Fit block with regulator up
(210-7) MP16
and with delivery flange left, viewed from
front side.
Counter clockwise rotation (Viewed from
input shaft side) - Fit block with delivery
flange right, viewed from front side.

(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
Take care not to mistake regulator of front
pump for that of rear pump.

(210-7) MP17

(10) Fit drain port plug (468).

This is the end of reassembling procedures.

8-18
3. REGULATOR (1/2)

412 876 874 755 858

A
897 B
612
614

615

613
A
875
A 611
P2
B Pf

Pi

438

C
B

641 730 643 708 644 645 646 728 924 801

SECTION B-B

2209S2MP03

438 656 413 438

Port Port name Port size
A Delivery port 3/4"
B Suction port 2 1/2"
735
Pi Pilot port PF 1/4-15
722
Pf Power shift port -
P2 Companion delivery port -

496 724 725 436

VIEW C

8-19
 REGULATOR (2/2)

655 734 653 654 836 651 652 601 624 629 630 628 802

641

814

898

631
732

733

622

621 623 625 626 887 763 756 753 627

SECTION A-A
21092MP04

412 Hexagon socket screw 630 Lock nut 733 O-ring

413 Hexagon socket screw 631 Sleeve, pf 734 O-ring
436 Hexagon socket screw 641 Pilot cover 735 O-ring
438 Hexagon socket screw 643 Pilot piston 753 O-ring
496 Plug 644 Spring seat (Q) 755 O-ring
601 Casing 645 Adjust stem (Q) 756 O-ring
611 Feed back lever 646 Pilot spring 763 O-ring
612 Lever (1) 651 Sleeve 801 Nut
613 Lever (2) 652 Spool 802 Nut
614 Fulcrum plug 653 Spring seat 814 Snap ring
615 Adjust plug 654 Return spring 836 Snap ring
621 Compensator piston 655 Set spring 858 Snap ring
622 Piston case 656 Block cover 874 Pin
623 Compensator rod 708 O-ring 875 Pin
624 Spring seat (C) 722 O-ring 876 Pin
625 Outer spring 724 O-ring 887 Pin
626 Inner spring 725 O-ring 897 Pin
627 Adjust stem (C) 728 O-ring 898 Pin
628 Adjust screw (C) 730 O-ring 924 Set screw
629 Cover (C) 732 O-ring

8-20
 2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket
Name B head bolt (PT thread) (PF thread) head setscrew

Allen wrench 4 M 5 BP-1/16 - M 8

B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double (single) Hexagon head VP plug
- Hexagon nut
open end spanner bolt (PF thread)
B

6 M 8 M 8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4100 mm
Torque wrench Capable of tightening with the specified torques
Pincers -
Bolt M4, Length : 50 mm

8-21
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfm lbfft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug (Material : S45C) PT1/16 0.7 5.1 0.16 4
Wind a seal tape 1 1/2 to PT 1/8 1.05 7.59 0.20 5
2 turns round the plug PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug (Material : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17

8-22
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
Choose a clean place.
Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.

(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
Take care not to lose O-ring.

(210-7) REG01

(4) Remove hexagon socket head screw

(438) and remove cover (C,629)
Cover (C) is fitted with adjusting screw
(C, 628), adjusting ring (C, 627), lock nut
(630), hexagon nut (801) and adjusting
screw (924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
(210-7) REG02

8-23
(5) After removing cover (C, 629) subassembly,
take out outer spring (625), inner spring
(626) and spring seat (C, 624) from
compensating section.
Then draw out adjusting ring (Q, 645),
pilot spring (646) and spring seat (644)
from pilot section.
Adjusting ring (Q,645) can easily be
drawn out with M4 bolt.
(210-7) REG03

(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover (641).
After removing pilot cover, take out set
spring (655) from pilot section.

(210-7) REG04

(7) Remove snap ring (814) and take out

spring seat (653), return spring (654) and
sleeve (651).
Sleeve (651) is fitted with snap ring (836).
When removing snap ring (814), return
spring (654) may pop out.
Take care not to lose it.

(210-7) REG05

(8) Remove locking ring (858) and take out

fulcrum plug (614) and adjusting plug
(615).
Fulcrum plug (614) and adjusting plug
(615) can easily be taken out with M6 bolt.

(210-7) REG06

8-24
 (210-7) REG07

(9) Remove lever (2, 613). Do not draw out

pin (875).
Work will be promoted by using pincers or
so on.

(210-7) REG08

(10) Draw out pin (874) and remove feedback

lever (611).
Push out pin (874, 4 mm in dia.) from
above with slender steel bar so that it may
not interfere with lever (1, 612).

(210-7) REG09

(210-7) REG10

8-25
(11) Remove lever (1, 612). Do not draw out
pin (875).
(12) Draw out pilot piston (643) and spool
(652).
(13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) ,
compensating piston (621) and
compensating rod (623).
Piston case (622) can be taken out by
pushing compensating rod (623) at
opposite side of piston case.

This completes disassembly.

8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
Always repair parts that were scored at
disassembly.
Get replacement parts ready beforehand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
Always tighten bolts, plugs, etc. to their
specified torques.
Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.

(2) Put compensating rod (623) into

compensating hole of casing (601).
(3) Put pin force-fitted in lever (1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.

(4) Fit spool (652) and sleeve (651) into hole

in spool of casing.
Confirm that spool and sleeve slide
smoothly in casing without binding.
Pay attention to orientation of spool.

Spool

Feedback lever
(210-7) 8-27

8-27
(5) Fit feedback lever (611), matching its pin
hole with pin hole in spool.
Then insert pin (874).
Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
Take care not to mistake direction of (fulcrum plug of
adjusting plug side)
feedback lever.

(210-7) 8-28

(6) Put pilot piston (643) into pilot hole of

casing.
Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever (2, 613) into
groove of pilot piston.
Then fix lever (2).

(210-7) REG11

(8) Fit fulcrum plug (614) so that pin force-

fitted in fulcrum plug (614) can be put into
pin hole of lever (2).
Then fix locking ring (858).
(9) Insert adjusting plug (615) and fit locking
ring.
Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. (210-7) REG12

(10) Fit return spring (654) and spring seat

(653) into spool hole and attach snap ring
(814).

(210-7) REG13

8-28
(11) Fit set spring (655) to spool hole and put
compensating piston (621) and piston
case (622) into compensating hole.
Fit pilot cover (641) and tighten it with
hexagonal socket head screws (436,
438).

(210-7) REG14

(12) Put spring seat (644), pilot spring (646)

and adjusting ring (Q, 645) into pilot hole.
Then fix spring seat (624), inner spring
(626) and outer spr ing (625) into
compensating hole.
When fitting spring seat, take care not to
mistake direction of spring seat.

(210-7) REG15

(13) Install cover (C, 629) fitted with adjusting

screws (628), adjusting ring (C, 627), lock
nut (630), hexagon nut (801) and
adjusting screw (924).
Then tighten them with hexagonal socket
head screws (438).

(210-7) REG16
This completes assembly.

8-29