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.
(4) Loosen the drain plug under the hydraulic 65
49
tank and drain the oil from the hydraulic 46
A1
tank. A2

 Hydraulic tank quantity : 70˶
(18.5 U.S.gal)
(5) Disconnect hydraulic hoses (22, 64, 65).
10
(6) Remove socket bolts (83) and disconnect
83
pump suction pipe (10). R5577DA01
ö When pump suction pipe is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan. 46
(7) Sling the pump assembly and remove the 64
pump mounting bolts.

 Weight : 30 kg (70 lb) 22 49
ö Pull out the pump assembly from housing. A4 A3

When removing the pump assembly,

check that all the hoses have been
disconnected.

555C97DA02

7-7
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.
Η Loosen the air vent plug.
Θ Start the engine, run at low idling, and
check oil come out from plug.
Ι 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.

7-8
2. MAIN PUMP
1) STRUCTURE

10 11 13 14 63 62

J
49
48
65 46
64 56
44
59 41
60
47
42 43 45
57
SECTION C-C SECTION D-D

12 59
9 15 21 22 27 31 32 23 36 37 38 39 28 33 58 35
53 34 68 72 70
18 30
8 71
29
2 69
5
6
1
67
4
3 DETAIL J
7 61
73

D D
C C
26 17 19 25 40 16 24 54 20 52 51 50 66 100

555C92SF06

1 Drive shaft 14 O-ring 27 Spring seat(1) 39 Shim 51 Valve plate 63 Snap ring
2 Seal cover 15 Pivot 28 Spring seat(2) 40 Control cylinder 52 Parallel pin 64 RO plug
3 Ball bearing 16 Cylinder block 29 Spring cover 41 Control piston 53 Socket bolt 65 O-ring
4 Snap ring 17 Bushing 30 Adjusting screw 42 Control push-rod(1) 54 O-ring 66 O-ring
5 Snap ring 18 Push plate 31 Spring 43 Control push-rod(2) 55 O-ring 67 Spool
6 Oil seal 19 Shoe plate 32 Spring 44 Spring seat(1) 56 Plug 68 Adjusting screw
7 O-ring 20 Spring 33 O-ring 45 Socket bolt 57 Orifice 69 O-ring
8 Snap ring 21 Parallel pin 34 Socket bolt 46 Conical spring washer 58 Needle bearing 70 Spring
9 Swash plate 22 Spring seat 35 Hex nut 47 O-ring 59 RP plug 71 Hex nut
10 Plate 23 Snap ring 36 Shim 48 O-ring 60 O-ring 72 Shim
11 Bearing spacer 24 Piston 37 Shim 49 O-ring 61 Socket bolt 73 Air breather
12 Roller bearing 25 Shoe 38 Shim 50 Valve block 62 Filter 100 Gear pump assy
13 Socket bolt 26 Pump casing

7-9
 2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Name Quantity Size (nominal)
Hexagonal bar spanner One each 5, 6, 8, 10
Spanner 1 17, 24
Plastic hammer 1 Medium size
Snap ring pilers 1 For hole (stop ring for 72)
Snap ring pilers 1 For shaft (stop rings for 28 and 30)
Standard screw-driver 2 Medium size
Wrench which can tighten at the
Torque wrench -
specified torque
Grease Small -
Adhesives Small LOCTITE #270

(2) Jigs
Η Disassembling table
͚35 ~ ͚55

45 or more

͚110 or more
R55NM7HP01

This is plate to stand the pump facing downward.

A square block may be used instead if the shaft end does not contact.

Θ Bearing assembling jig

40

15

͚19

͚25

R55NM7HP02

7-10
 (3) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft in mm
Hexagon socket head bolt M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M12 10.0 72.3 0.39 10
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
PT Plug PT 1/16 0.9 6.5 0.16 4
PF Plug PF 1/8 1.5 10.8 0.20 5
PF 1/4 3.0 21.7 0.24 6

7-11
3. DISASSEMBLY PROCEDURE
1) DISASSEMBLING THE GEARED PUMP
Η Remove the hexagonal socket headed
bolts (M10 Ý 25, 2 pieces).
Hexagonal bar spanner
(Hex. side distance : 8)
ö
Be careful because the O-ring and filter
are provided to the match surface of the
geared pump.

R55NM7HP03

Θ
Remove the coupling.

R55NM7HP04

2) DISASSEMBLING THE MAIN PUMP

Η Remove the cover.
Remove the hexagonal socket headed
bolts. (M12 Ý 30, 3pieces) and (M12Ý
55, 1piece).
Hexagonal bar spanner
(Hex. side distance : 10)

R55NM7HP05

Θ
Remove the cover in a horizontal

condition.
Connect motor to work table.
ö Be careful because the control plate is
provided to the backside.
When the cover is difficult to remove,
knock lightly with a plastic hammer.

R55NM7HP06

7-12
 Ι
This photo shows the state with the cover
removed.

R55NM7HP07

Κ
Remove the O-ring from the cover.

R55NM7HP08

(1) The removal of the control spring

Η Remove 2 springs (inner and outer).

R55NM7HP09

Θ Remove the spring seat.

R55NM7HP10

7-13
(2) The removal of rotary group
Η Lay the pump on the side and take out
the rotary group from the shaft.

R55NM7HP11

Θ Remove the plate.

R55NM7HP12

(3) The removal of the shaft

Η Remove the C-type stop ring.
(snap ring pliers for hole)

R55NM7HP13

Θ Use two standard screw-drivers to

remove the oil seal case.

R55NM7HP14

7-14
Ι
Remove the O-ring.

R55NM7HP15

Κ
Remove it while knocking the shaft rear

and lightly with a plastic hammer.

R55NM7HP16

(4) The removal of the hanger

Η Remove the hexagonal socket headed
bolts (M6 Ý 16, 4pieces) and plate.
Hexagonal bar spanner
(Hex. side distance : 5)

R55NM7HP17

Θ Remove the distance piece.

R55NM7HP18

7-15
 Ι
Remove the bearing.

R55NM7HP19

Κ
Remove the hanger.

R55NM7HP20

(5) The removal of the cover

Η Remove the control plate.

R55NM7HP21

Θ Remove the C-type stop ring.

R55NM7HP22

7-16
Ι
Remove the filter.

R55NM7HP23

(6) The removal of the control piston

Η Remove the hexagonal socket headed
bolts. (M8 Ý 25, 2pieces)
Hexagonal bar spanner
(Hex. side distance : 6)
The threaded portion of the bolt is
coated with LOCTITE #270.
This disassembly must therefore be
made only when necessary.
R55NM7HP24

Θ Remove the cylinder and parallel pin.

ö Be careful because 3 O-rings are provided
to the cylinder.

R55NM7HP25

Ι
Take out the piston.

R55NM7HP26

7-17
 Κ
Take out three caned disk springs and
spring seats.

R55NM7HP27

(7) The removal of the control spring

Η Remove the hexagonal socket headed
bolts (M8Ý30, 2pieces) and remove the
cover.
Hexagonal bar spanner
(Hex. side distance : 6).

R55NM7HP28

Θ Remove the spring seat.

R55NM7HP29

7-18
(8) The removal of the relief valve
Η Remove the hexagonal nuts.
ö Since the pressure has been set, this
assembly must be made only when
necessary.
Spanner (Hex. side distance : 24).

R55NM7HP30

Θ Remove the adjusting screw.

ö Be careful because the shim is inserted.

R55NM7HP31

Ι
Remove the spring.

R55NM7HP32

Κ
Remove the spool.

R55NM7HP33

7-19
(9) Disassembly of the shaft
Η Remove the bearing.
Remove the C-type stop ring.
Snap ring pliers for shaft.

R55NM7HP34

Θ Remove it while knocking the rear end of

shaft lightly with a plastic hammer.

R55NM7HP35

7-20
3) DISASSEMBLING THE GEARED PUMP
(1) Disassembling the P3 and P4 pump
Η Removed hexagonal socket head bolt
and nut.
Hexagonal socket wrench (8 mm).
Hexagonal bar spanner (17 mm).

R55NM7HP209

(2) Disassembling the geared pump (P4)

Η Remove the geared pump (P4) from the
center frame.

R55NM7HP208

Θ Pulling out the drive gear and the idle

gear.

R55NM7HP207

Ι Remove the O-ring from the center

frame.

R55NM7HP206

7-21
(3) Disassembling the geared pump (P3)
10
Η Remove the square ring (10).

R5577MP01

Θ Remove the plate (5) and the guide ring 5 8 6

(pieces). With O-ring (6, 8).
Remove the O-ring (8) from guide ring
(6).

R5577MP02

Ι Remove the drive and idle gear (2, 3)

and the side plate (4) assembly.
4 2 3 4

R5577MP04

Κ Remove the plate 5

R5577MP03

7-22
4. ASSEMBLING PROCEDURE
1) ASSEMBLING THE MAIN PUMP
(1) Assembling the hanger.

R55NM7HP50

(2) Install the bearing.

R55NM7HP50A

(3) Install the distance piece.

Confirm that pre-load is 0.1 Ü 0.2.

R55NM7HP51

(4) Fix the plate with the hexagonal socket

headed bolts (M6 Ý 16, 4pieces).
Hexagonal bar spanner
(Hex. side distance : 5)
Tightening torque : 1.2 ~ 1.5 kgfÂm
(8.7 ~ 10.8 lbfÂft)

R55NM7HP52

7-23
(5) Assembling the shaft
Η Fit the shaft into the bearing (with the
bearing in the bottom) by using the press
machine and jig. If the press is not
available, use the jig in the similar
manner and drive the shaft into the
bearing by knocking with a plastic
hammer.

R55NM7HP53

Θ Install the C-type stop ring to fix the

bearing.

R55NM7HP54

Ι
Assembling the shaft.

Assemble the shaft into the housing.
Knock the spline end lightly with a plastic
hammer and fix the bearing outer ring
firmly into the housing hole.

R55NM7HP55

(6) Apply grease to the O-ring for assembling.

R55NM7HP56

7-24
(7) Install the case with oil seal vertically
without tilting.
ö Apply grease to the oil seal lip beforehand.

R55NM7HP57

(8) Install the C-type stop ring to fix the shaft.

R55NM7HP58

(9) Assembling the rotary group.

Install 10 (ten) pistons into the retainer.

R55NM7HP59

(10) Apply grease to 3 parallel pins and

assemble them to the cylinder block.

R55NM7HP60

7-25
(11) Apply grease to the spherical portion of
the guide.

R55NM7HP61

(12) Insert the guide between the retainer and

cylinder block and assemble the piston
into the hole of cylinder block.

R55NM7HP62

(13) Assembling the rotary group.

To prevent dislodgement, apply grease to
the back side of the plate and assemble it
to the hanger.

R55NM7HP63

(14) Assemble the rotary group along the

shaft spline.
ö During assembly, apply grease to the
slide surface of piston shoe and to the
slide surface of the cylinder block relative
to the control plate.

R55NM7HP64

7-26
(15) Assembling the control spring.
Apply grease to the spherical portion of
the spring seat before assembling.

R55NM7HP65

(16) Assemble 2 springs (inner and outer).

R55NM7HP66

(17) Assembling the cover.

Assemble the spring seats and coned
disk springs (3 pieces).

R55NM7HP67

(18) Assembling the control piston.

R55NM7HP68

7-27
(19) Apply grease to the O-rings
(5.28Ý1.78, 1piece), (7.65Ý1.78, 1piece)
and (15.6Ý1.78, 1piece) and assemble
them to the cylinder.

R55NM7HP69

(20) Apply grease to 3 parallel pins and

assemble 3 pins into the cylinder.

R55NM7HP70

(21) Fix the cylinder with the hexagonal socket

headed bolts (M8Ý25, 2pieces).
ö Apply LOCTITE #270 to the threaded
portion of bolt.
Hexagonal bar spanner
(Hex. side distance : 6)
Tightening torque : 2.9 ~ 3.5 kgfÂm
(21 ~ 25.3 lbfÂft)

R55NM7HP71

(22) Assembling the control spring.

Install the spring seat.

R55NM7HP72

7-28
(23) Fix the cover with the hexagonal socket
headed bolts (M8Ý30, 2pieces)
Hexagonal bar spanner
(Hex. side distance : 6)
Tightening torque : 2.9 ~ 3.5 kgfÂm
(21 ~ 25.3 lbfÂft)

R55NM7HP73

(24) Apply grease to the back side of the

control plate and assemble it to the cover
while matching knock holes.

R55NM7HP74

(25) Install the O-ring.

Assemble the spring seats and coned
disk springs (3pieces).

R55NM7HP75

(26) Install the filter into the cover.

R55NM7HP76

7-29
(27) Fix the filter with the C-type stop ring.

R55NM7HP77

(28) Assembling the relief valve.

Assemble the spool.

R55NM7HP78

(29) Assemble the spring.

R55NM7HP79

(30) Insert the shim into the adjusting screw.

R55NM7HP80

7-30
(31) Assemble the adjusting screw.

R55NM7HP81

(32) Tighten the hexagonal nuts.

After assembling, set the pressure and
tighten the nuts.
1 kgfÂm (7.2 lbfÂft)
Spanner (Hex. side distance : 24)

R55NM7HP82

(33) Install the cover in a parallel direction to

the housing mounting surface.

R55NM7HP83

(34) Fix the cover with the hexagonal socket

headed bolts (M12Ý30, 3pieces) and
(M12Ý55, 1piece)
Hexagonal bar spanner
(Hex. side distance :10)
Tightening torque : 10 ~ 12.5 kgfÂm
(72.3 ~ 90.4 lbfÂft)

R55NM7HP84

7-31
(35) Install the O-ring into the cover.

R55NM7HP85

(36) Install the coupling to the shaft end of the

main pump.

R55NM7HP86

(37) Connect the main and geared pump.

R55NM7HP87

(38) Fix the geared pump with the hexagonal

socket headed bolts (M10Ý25, 2pieces).
Hexagonal bar spanner
(Hex. side distance : 8)
Tightening torque : 5.6 ~ 7.0 kgfÂm
(40.5 ~ 50.6 lbfÂft)

R55NM7HP88

7-32
4) REASSEMBLING THE GEARED PUMP 5
(1) Reassembling the geared pump (P3)
Η Insert the plate (5) to the pump housing.

R5577MP03

Θ Insert the square ring into the side plate.

ö Be careful to suction and discharge side.

R55NM7HP210

Ι Assemble the side plate to the drive and

idle gear.

R55NM7HP211

Κ Assemble the gear assembly into the

gear casing.
4 2 3 4

R5577MP04

7-33
Λ Assemble the O-ring to the guide ring
and assemble them to the plate.

R55NM7HP213

Μ Assemble the guide ring assembly (6, 8) 5

and plate (5) to the gear casing.

R5577MP03

Ν Assemble the square ring (10) to the

10
gear casing.

R5577MP01

7-34
(2) Reassembling the geared pump (P4)
Η Insert the drive gear into the gear casing.

R55NM7HP219

Θ Insert the idle gear to into the gear

casing.

R55NM7HP220

Ι Insert the pins (2-pieces) to the center

frame.

R55NM7HP221

Κ Assemble the O-ring to the center frame.

R55NM7HP222

7-35
 Λ Assemble the center frame sub-
assemble to the gear casing sub-
assembly.

R55NM7HP223

(3) Reassembling the P3 and P4 pumps

Η Insert the pins (2-pieces) into the center
frame.

R55NM7HP224

Θ Insert coupling to the P3 geared pump.

R55NM7HP225

Ι Assemble the P3 and P4 geared pumps.

R55NM7HP226

7-36
Κ Assemble the hexagonal socket bolts
and nuts.
 Size : M10Ý65L, 4pieces
 Allen wrench : 8 mm
 Spanner : 17 mm
 Tightening torque : 580 kgfÂcm
(56.9 NÂm)

R55NM7HP227

Λ Assemble the O-ring to the pump

housing.

R55NM7HP228

7-37