GROUP 3 PUMP DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious
13031GE18
injury.
(3) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank.
1
·Hydraulic tank quantity : 450ℓ A2
A1
2
(4) Remove socket bolts(5) and disconnect
B1
hose (1,2). 5

(5) Disconnect pilot line hoses (6, 7, 8, 9, 10, 5

4
11, 12, 13, 14).
3
(6) Remove bolts (4) and disconnect pump 80098MP01

suction tube (3).

※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(7) Sling the pump assembly and remove the 10 9
8
pump mounting bolts. 14
·Weight : 300 kg (660 lb)
※ Pull out the pump assembly from housing. 11

When removing the pump assembly, 7

check that all the hoses have been 13
12
disconnected. 6

80098MP02

8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace the return filter with a 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.
① Remove the air vent plug (2EA)
② Tighten plug lightly
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.

(7) Start the engine, run at low idling (3~5

minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.

8-8
 2. MAIN PUMP (1/2)
1) STRUCTURE
466
789 732 532 214 548 531 724 702 792 534 954 725 901 718 706 114 717 151 152 416 407
535 490
808
953
887
717
406
261 Gear pump

111

774
824 B
113
127
123 263
710 B 468
728
251
401
253 497 212 211 153 156 157 313 956 124 311 887 130 415 312 885 314 012 271 981 253 402
983

491 492
Section B - B 80092MP07

012 Cylinder block 311 Valve cover (F) 702 O-ring

111 Drive shaft (F) 312 Valve cover (R) 706 O-ring
113 Driven shaft (R) 313 Valve plate (R) 710 O-ring
114 Coupling 314 Valve plate (L) 717 O-ring
123 Roller bearing 401 Hexagon socket bolt 718 O-ring
124 Needle bearing 402 Hexagon socket bolt 724 O-ring
127 Spacer 406 Hexagon socket bolt 725 O-ring
130 Booster 407 Hexagon socket bolt 728 O-ring
151 Piston 415 Hexagon socket bolt 732 O-ring
152 Shoe 416 Hexagon socket bolt 774 Oil seal
153 Plate 466 VP Plug 789 Back up ring
156 Bushing 468 VP Plug 792 Back up ring
157 Cylinder spring 490 VP Plug 808 Hexagon head nut
211 Shoe plate 491 Restorictor 824 Snap ring
212 Swash plate 492 VP Plug 885 Pin
214 Bushing 497 VP Plug 887 Spring pin
251 Support plate 531 Tilting pin 901 Eye bolt
253 Washer 532 Servo piston 953 Set screw
261 Seal cover (F) 534 Stopper (L) 954 Set screw
263 Seal cover (R) 535 Stopper (S) 956 Set screw
271 Pump casing 548 Feed back pin

8-9
 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

Allen wrench Hexagon socket PT plug PO plug Hexagon socket

B
head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
5 M 6 BP1/ 8 - M10
B 6 M 8 BP-1/ 4 PO-1/4 M12, M14
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, VP plug

- Hexagon head bolt Hexagon head bolt
socket wrench, double (PF thread)
(Single) 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. 10×8×200
Torque wrench Capable of tightening with the specified torques

8-10
 (2) Tightening torque

Torque Wrench size

Part name Bolt size
kgf·m lbf·ft in mm
Hexagon socket head M 5 0.7 5.1 0.16 4
bolt
(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 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
M22 64.0 462.9 0.67 17
PT plug PT 1/16 0.7 5.1 0.16 4
(Material : S45C)
※ Wind a seal tape 1 PT 1/ 8 1.05 7.59 0.20 5
1/2 to 2 turns round PT 1/ 4 1.75 12.66 0.24 6
the plug
PT 3/ 8 3.5 25.3 0.31 8
PT 1/ 2 5.0 36.2 0.39 10
PF plug PF 1/ 4 3.0 21.7 0.24 6
(Material : S45C)
PF 1/ 2 10.0 72.3 0.39 10
PF 3/ 4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17

8-11
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.

36078MP02

(5) Loosen hexagon socket head bolts (401)

which tighten swash plate support (251),
pump casing (271) and valve cover (F,
311).
※ If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.

(6) Loosen hexagon socket head bolts (402)

which tighten swash plate support (251),
pump casing (271) and valve cover (R,
312).

8-12
(7) Place pump horizontally on workbench
with its regulator-fitting surface down, and
separate pump casing (271) from valve
cover (F, 311).
※ Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.

36078MP03

(8) Separate valve cover (F, 311) from valve

cover (R, 312) and pull out booster (130),
spline coupling (114).

(9) Separate valve cover (R, 312) from pump

casing and then pull out the cylinder block
(012) of pump casing (271) straightly over
drive shaft (R, 113). 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. 36078MP04

(10) 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 when removing
cover.

36078MP05

8-13
(11) Tapping lightly fitting flange section of
swash plate support (251) on its pump
casing side, separate swash plate support
from pump casing.

36078MP06

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

(212) from pump casing (271).

36078MP07

(13) Tapping lightly shaft ends of drive shafts

(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.

36078MP08

8-14
(14) Remove valve plates (313, 314) from
valve cover (311, 312).
※ These may be removed in work 7, 9.

36078MP09

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

stopper (S, 535), servo piston (532) and
tilting pin (531) from pump casing (271),
and needle bearing (124) from valve
cover (311, 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
cover and swash plate support.
If loosened, flow setting will be changed.

(16) This is the end of disassembling procedures.

8-15
4) ASSEMBLY
(1) For reassembling reverse the disassem-
bling procedures, paying attention to the
following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
② Clean each part fully with cleaning oil
and dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
⑥ 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
36078MP10
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 support (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
36078MP11
shaft can be fitted easily.

To (4) 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.
36078MP12

(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.
36078MP13

(6) Assemble piston cylinder subassembly

〔c y l i n d e r bl o ck ( 0 1 2 ) , p i s t o n
subassembly (151, 152), set plate (153),
spherical bushing (156) and cylinder
spring (157)〕.
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing (271).

36078MP14

8-17
(7) Fit valve plate (313) to valve cover (F,
311), and fit valve plate (314) to valve
cover (R, 312), entering pin into pin hole.
※ Take care not to mistake suction / delivery
directions of valve plate.

36078MP15

(8) Fit valve block (R, 312) to pump casing

(271) and fit spline coupling (114) and
booster (130) to shaft (R, 113).
※ Take care not to mistake direction of valve
cover.
Fit valve cover with regulator up and with
delivery flange left, viewed from front side.
※ Take care not to mistake direction of
booster (130).
36078MP16
(Refer to the sectional drawing)

(9) Fit valve cover (F, 311) to valve cover (R)

and tighten hexagon socket head bolts
(402).

(10) Fit pump casing (271) with shaft (F, 111)

to valve cover (F, 311) and tighten
hexagon socket head bolts (401).
※ Mate spline phases of shaft (F) and spline
coupling, with shaft (F) been rotating.

36078MP18

8-18
(11) 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.

36078MP17

(12) Fit drain port plug (468).

This is the end of reassembling procedures.

8-19
5) REGULATOR (1/2)

80092RG01

Port Port name Port size

Pi Pilot port PF 1/4 - 15
Psv Servo assist port PF 1/4 - 15
P2 Companion delivery pressure -
Pf Powershift pressure -

8-20
 REGULATOR (2/2)
734 653 654 836 651 652 601 624 629 630 628
655

641 802

814

898

631 627
732
753
733

622

621 623 625 626 887 763 756

SECTION A-A 8007A2RG02

408 Hexagon socket screw 627 Adjust stem(C) 725 O-ring

412 Hexagon socket screw 628 Adjust screw(C) 728 O-ring
413 Hexagon socket screw 629 Cover(C) 730 O-ring
436 Hexagon socket screw 630 Lock nut 732 O-ring
438 Hexagon socket screw 631 Sleeve, pf 733 O-ring
439 Hexagon socket screw 641 Pilot cover 734 O-ring
466 Plug 643 Pilot piston 735 O-ring
496 Plug 644 Spring seat(Q) 753 O-ring
541 Seat 645 Adjust stem(Q) 755 O-ring
543 Stopper 1 646 Pilot spring 756 O-ring
545 Steel ball 647 Stopper 763 O-ring
601 Casing 648 Piston(QMC) 801 Nut
611 Feed back lever 651 Sleeve 802 Nut
612 Lever(1) 652 Spool(A) 814 Snap ring
613 Lever(2) 653 Spring seat 836 Snap ring
614 Center plug 654 Return spring 874 Spring pin
615 Adjust plug 655 Set spring 875 Pin
621 Compensator piston 696 Port cover 876 Pin
622 Piston case 697 Check valve plate 887 Pin
623 Compensator rod 698 Cover 897 Pin
624 Spring seat(C) 708 O-ring 898 Pin
625 Outer spring 722 O-ring 924 Set screw
626 Inner spring 724 O-ring

8-21
 6) 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
Hexagon socket PT plug PO plug
Name B socket
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, Hexagon head VP plug
Hexagon nut
socket wrench, double bolt (PF thread)
(Single) open end -
spanner
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 4×100 mm
Torque wrench Capable of tightening with the specified torques
Pincers -
Bolt M4, Length : 50 mm

8-22
 (2) Tightening torque

Torque Wrench size

Part name Bolt size
kgf·m lbf·ft 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 PT 1/8 1.05 7.59 0.20 5
to 2 turns round the
PT 1/4 1.75 12.7 0.24 6
plug
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

8-23
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.

REG01 (210-7)

(4) Remove hexagon socket head screw

(438) and remove cover (C,629)
※ Cover (C) is fitted with adjusting screw
(C,QI) (628, 925), 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.
REG02 (210-7)

8-24
(5) After removing cover(C, 629) subassemb-
ly, 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.
REG03 (210-7)

(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.

REG04 (210-7)

(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.

REG05 (210-7)

(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.

REG06 (210-7)

8-25
 REG07 (210-7)

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

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

REG08 (210-7)

(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).

REG09 (210-7)

REG10 (210-7)

8-26
(11) Remove lever(1, 612). Do not draw out
pin (875).
(12) Draw out pilot piston(643) and spool(652).
(13) Draw out piston case(622), 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.

8-27
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
② Get replacement parts ready before-
hand.
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.
③ Always tighten bolts, plugs, etc. to their
specified torques.
④ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
⑤ Replace seals such as O-ring with new
ones as a rule.

(2) Put compensating rod (623) into compen-

sating 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
8-27 (210-7)

8-28
(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.
(Fulcrum plug of
※ Take care not to mistake direction of
adjusting plug side)
feedback lever.

8-28 (210-7)

(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).

REG11 (210-7)

(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. REG12 (210-7)

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

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

REG13 (210-7)

8-29
(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).

REG14 (210-7)

(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 spring (625) into compen-
sating hole.
※ When fitting spring seat, take care not to
mistake direction of spring seat.

REG15 (210-7)

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

screws (628, 925), adjusting ring (C, 627),
lock nut (630), hexagon nut (801) and
adjusting screw (924).
Then tighten them with hexagonal socket
head screws (438).

This completes assembly. REG16 (210-7)

8-30