Group 4 Disassembly and Assembly: 1. Main Pump
Group 4 Disassembly and Assembly: 1. Main Pump
Group 4 Disassembly and Assembly: 1. Main Pump
1. MAIN PUMP
1) STRUCTURE
P2 CARTRIDGE
27
34 39
35 1
20 26
17 21 22
16 21
P1 CARTRIDGE 19
8
7707WE28
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STRUCTURE(2/2)
37
36 28
38
29
7
9
11
6
10
32
25
30
24
31
12
33
5 11
23
4
3
13
2
14
15
P2 CARTRIDGE P1 CARTRIDGE
7707WE29
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2) GENERAL INSTRUCTION
(1) Preliminary
※ Any servicing work done on main pump is to be done in a clean environment to prevent potential
contamination by foreign particles.
※ Appropriate tools and equipment are required in order to insure proper disassembly and
reassembly in suitable conditions. In case of repetitive service, a specific working bench is
recommended.
※ To prevent oil leakage and body tilting during assembly, housing bolts are to be tightened as per
the following pattern !
1 3 3 1
5 6
7 4
4 2 2
7803AWE05
(2) Parts
※ Parts must be kept clean at all time. If cleaning is needed, solvent is to be used. It is needed to
check and oil the inner parts before assembly.
※ In case of replacement of parts with mulitiple numbers, such as vanes and holdout pins, all the
parts are to be changed.
① Vanes
The faces and edges should be free of scratch from contamination. Vanes should move
smoothly in the rotor slots, without excessive clearance. Edges may be stoned with a fine lndia
stone to remove burrs.
② Vane holdout pins :
Holdout pins should have no matting marks.
Vane
Rotor
Pin
7803AWE50
③ Rotor :
Side surfaces and vane slots should be free of scratches. Side feeds, vane slots and holdout pin
orifices should be free of any contamination. Serration(driving splines) should not be deformed
by the shaft.
7803AWE51
6 -60
④ Camring :
No scratches or vane shock marks(waves) should be seen. Visual axial waves on new camring
are from grinding process and therefore normal.
7803ASE06
⑤ Port plates :
Faces should not be scratched. No cavitation/aeration/fretting corrosion marks should be seen.
When there, the bronze bushing should be clean, with no abnormal wear sign.
Bi-directional cartridges use same port plates for CW and CCW rotation. Unit-directional
cartridges require different port plates.
7803ASE08
⑥ Seals :
・ All oil seals must be cleaned, with no wear or cutting mark. When servicing a pump from field
operation, it is highly recommended to change all seals. All seals are to be greased lightly
before assembly.
・ Use seal driver tool to install shaft seal, and protective cone to install shaft assembly.
・ Backup rings(1) on pressure plates are to be replaced, anytime a cartridge is taken out of a
pump. Backup rings are to be installed as follow, behind the square seal :
7803ASE07
⑦ Shaft :
・ Key-way should be clean and not worn on the sides by excessive torque. No fretting corrosion
due to poor coupling should be visible. On spline shaft, splines should not be deformed.
・ No axial scratch should be on the sealing area(1). The shaft seal lip contact line may be visible,
but should not be a groove. Bronze-bushing contact area(2) should be clean and cylindrical,
without scratch marks.
6 -61
2 4 1
7803ASE10
・ Ball bearing(3) should turn freely and snap ring(4) should be in place. Some shaft assemblies
have 2 snap rings, before and after the ball bearing.
※ Never insert a snap ring from shaft seal side, to avoid scratching the sealing surface.
※ Use protective cone to install shaft assembly. If not available, make sure not to damaged the
shaft seal lips.
(3) Pre start check and priming.
① Before operating the pump again, the following points are to be checked :
・ Pump rotation is as per electric motor or engine.
・ All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
・ If any, valve on suction line is to be fully opened.
② When electric motor or engine is started up, the pump should prime immediately. However,
depending on installation and amount of air in the discharge lines, priming may take a few
seconds.
③ In case priming does not occur within 15 seconds, equipment should be switched off at once.
・ Then :
・ Manually fill the pump housing with fluid.
・ Bleed off air that may be trapped in the pump.
・ Check air bleed-off valves.
・ Start rotation in a jogging manner until a prime is picked up.
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3) DISASSEMBLY
(1) Install the pump on the table.
※ Two bolts will help to unscrew the 4 pump
bolts.
(2) Unscrew the bolts.
7707WE31
7707WE32
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(4) Disassemble the P2 cartridge/end cap
with an extractor.
※ If you want to continue the pump disasse-
mbly(P1 & shaft), go to page 6-65.
※ If you want to reassemble the P2 cartrid-
ge, go to page 6-66.
7707WE33
7707WE34
7707WE35
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(7) Remove the front cap.
※ P1 cartridge will come with the front cap /
shaft assembly.
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7707WE37
7707WE38
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(9) The pump is now disassembled.
4) ASSEMBLY
(1) Fit the cartridge P1 into the housing.
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7707WE41
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A : Protective cone on the shaft assembly.
B : Shaft assembly + protective cone into the
front cap. Slightly rotate the shaft to avoid C
the shaft seal lip(s) to be deteriorated.
C: Retaining ring into the front cap.
ö To avoid damaging the shaft seal do not
forget to put a protective cone on the B
shaft.
ö Push on the external bearing cage.
7707WE42
7707WE43
6 -67
① Always check if the shaft rotates freely.
If not, disassemble and go back to the 19.1Kgf.m(138lbf.ft)
previous step.
② Check the porting configuration.
③ Tighten the 4 bolts.
1 4
Step by step to
avoid damaging
the seals.
3 2
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7707WE45
6 -68
(6) Assemble the end cap on the housing assy.
※ Position the shaft / front cap assy only if the
cartridge is well positioned, dowel pin in the
housing dowel pin hole.
※ Put some grease on the seals to prevent
them from moving.
※ Always check if the shaft rotates freely.
If not, disassemble and go back to the
previous step.
7707WE46
1 4 1 4
6 7
3 2
3 2 5
7707WE47
6 -69
2. MAIN CONTROL VALVE
1) STRUCTURE
10 17
7 9
7
11
12
16
13
10
6
14
17
5
7
8
2 15
4.2kgf.m(30.4lbf.ft)
6
2
7707WE50
6 -70
2) DISASSEMBLY AND ASSEMBLY
※ Ensure that the machine is in a safe condition with no suspended loads or trapped pressure within
the system before removing any pipework or component.
Servicing must only be carried out by trained personel.
(1) MAIN RELIFE VALVE(Item 2)
① Removal
Unscrew both the pilot assembly and the plug from both ends of the relief valve. The main stage
assembly must be driven or pressed out in the direction of the pilot assembly using a soft drift.
② Refitting
Lubricate sleeve and assemble by pressing into housing until detent ring(12) locates on housing.
Fit the pilot assembly and end cap.
③ Adjusting
The main relief valve must be adjusted to the required setting when the machine is recommissioned.
Adjustment is made by first unscrewing the adjuster(1) until there is no load on the pilot spring(10).
Select a machine service to its end stop.
Screw in the adjuster until the correct pressure setting is measured at the valve inlet, account must
be taken for the effect of back pressure on the measured setting.
8
1
16
3 15.5kgf.m(112lbf.ft)
14
10
5
Pil
ot 7
as
sy
9
12
17
4
6
Ma 15
in 13
sta 11
ge 14
as
sy 2
15.5kgf.m(112lbf.ft) 7707WE51
6 -71
(2) DOUBLE ACTING SPOOL(Item 3, 4) 4
Control spools are not replaceable as they 3
2
are individually sized to suit the housing.
Bucket spool
When removing and refitting spools ensure
that they are refitted into the correct bore 1
and correctly orientated as shown by the
identification groove location on the valve 2
3
assembly drawing. 4
1 Spool 3 Spring
2 Plunger 4 O-ring
Boom spool
7707WE52
8
3.1kgf.m(22.4lb.ft)
2
3
6
10
1 5
3.1kgf.m(22.4lb.ft)
6
9
7
16
4
12
9 15
9.7kgf.m(70.2lb.ft)
17
9.7kgf.m(70.2lb.ft)
7707WE53
6 -72
(4) BOOM SPOOL CENTERING(Item 6)
Remove 4 retaining screws(8) from the spring centering end. Remove the cover(1) and withdraw the
spring pack and spool from the valve.
Hold the spool in a suitable soft clamp being careful not to damage the spool surface or bend the
spool. Remove the spool caps from the spool. The replacement assembly is supplied with the spring
set to the correct load. Refit the spool caps to the specified torque using loctite 542 or similar medium
strength oil tolerant thread locking product.
16
15
17
2
6
8
10,11,13
1
3
6
3.1kgf.m(22.4lbf. ft) 9
7
18
5 4
12
17
15
9.7kgf.m(70.2lbf. ft) 16
9.7kgf.m(70.2lbf. ft)
9
19
14
7707WE54
6 -73
(5) COMBINED OVERLOAD AND ANTI-CAVITATION(Item 7)
This is a non servicable item and a replacement unit factory set to the correct setting should be fitted.
Inspect seat in valve housing for damage before refitting.
10
5 3
12
6
9
15 14
13
10
9.7kgf.m(70.2lbf.ft)
2
4
8
11
8.7kgf.m(62.9lbf.ft)
1
7
3.1kgf.m(22.4lbf.ft)
7707WE55
0.51kgf.m(3.7lbf.ft)
6 -74
(7) CHECK VALVE ASSEMBLY(Item 9, 16)
This is a non servicable item and a
7
replacement unit should be fitted. 1
Ensure that orifice in check valve(1) is clear
6
when refitting. Inspect seat in float check
5
block for damage before refitting. 4
8
1 Float check valve 6 Spring
2
2 Housing 7 Composite piston seal
4 O-ring 8 O-ring
5 Back up ring
7.6kgf.m(55lbf.ft)
7707WE57
15
12
11
10
7
9
6
8
5
3
4
17 2
16
1
7707WE58
6 -75
(9) PILOT OPERATED FLOAT CHECK BLOCK ASSEMBLY(Item 11)
Remove the three retaining screws(2) and
lift the block from the main housing. 2 3
Do not slide the block accross the face as
this may damage the sealing face and 1 3
seals. 78
8 7
6
3 3
4 5
3
4
2
1
1 Adapter
2 Socket set screw
3 Check valve
4 O-ring
7707WE60
1 Seat
2 Metric ball
3 O-ring
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(12) A/C CHECK VALVE ASSEMBLY(Item 14)
This is a non servicable item and a
replacement unit should be fitted. Inspect
seat in float check block for damage before 4
refitting. 2
3
1 Body 4 Piston seal 5
2 Check valve 5 O-ring
3 Spring 1
7707WE62
13
12
0.51kgf.m(3.7lbf.ft)
11
10 4.6kgf.m(33.2lbf.ft)
7
9
68 16
5
4
15
14
16
3
1
2
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3. REMOTE CONTROL VALVE
1) STRUCTURE
2
1
3-1
3-2
Locite 262
3-3
5
11-1
11-2 12-1
4,3,1 12-2
4 1
10 3 2
30
11-3 12-3
11-4 12-4
2
33 30
11-5
11-6
4,3,1 14 32
40
15
40
4 1
20-1 42
20 3 2
22
21
23 4 1
3 2
25
26
7707WE64
6 -78
2) DISASSEMBLY AND ASSEMBLY
(1) PUSH BUTTEN
The remote control valve does not need to be removed from the machine to perfom this operation.
Remove worn pushbutton using a small screwdriver.
The installation of new elements is performed without any special tools; the parts are simply
pressed into place.
(2) RUBBER BOOT
① Remove the remote control valve from the machine or free the valve by unscrewing the 4 screws
fixing the plate in order to release the electrical cable.
・Assembly
Torque : 1.02kgf・m(7.4lbf・ft)
Hold the remote control valve using a vice or a vice-grip wrench(clamp onto the body).
※ The pilot unit does not need to be removed from the machine to release the cable. However, it is
recommended to lift the control unit by undoing the 4 fixing screws on the arm rest.
※ It is unnecessary to remove the units with no electrical functions.
② Lift and turn the boot inside out.
③ Remove the grommet(7) from its emplacement to free the cable.
④ Loosen the handle mounting nut(3-3) using a 19mm open-end wrench.
・Assembly : torque 4.08kgf・m(29.5lbf・ft)
⑤ Unscrew and remove the handle(1).
・Assembly
- Add loctite 262 onto the lever thread
- Torque : 4.08kgf・m(29.5lbf・ft)
⑥ Replace the faulty rubber boot(4) with a new one.
⑦ Replace the handle(1) following the disassembly instructions in reverse order.
(3) HANDLE
① Clamp the threaded section of the lever(3-2) in a vice fitted with V-shaped vice clamp.
② Remove the pin(3-1) using a 5mm pin driver.
③ Replace the lever(3-2) onto the new handle(1) and secure it with the pin(3-1) using a 5mm pin
driver.
※ Respect the position of the curved lever to ensure that the handle is correctly oriented as
indicated by the machine’s technical specifications.
④ Replace the nut(3-3) on the threaded section and replace the boot(4).
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(4) DETENT CARDAN BRACKET KIT
※ Remove the 2 grommets(20-1) from the W
flange (20).
V
※ Place centering sleeves V & W to avoid
damaging the cardan knuckles while
loosening the nuts.
※ Unscrew the locking nut(5) using a
23mm open-end wrench.
・Assembly : Torque 4.08±0.4kgf・m
(29.5±2.9lbf・ft)
① Unscrew the self-locking nut(11-1) using Before loosening the nuts
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(8) INTERMEDIARY PLUNGER KIT
① Undo the intermediary plunger guide(23).
② Remove and replace the intermediary plunger kit assembly(22).
(9) GUIDE / PLUNGER AND REGULATION UNIT
※ Beware of the plungers that might jump out due to the spring return.
① Remove : - Guide/plunger assembly(30).
- Regulation unit(32/33).
- Return spring(40).
- Pre-feeling point kit(42).
② The remote control valve is now totally disassembled.
Assemble in reverse order following the torque specification.
6 -81