Scag Power Equipment | SCAG SCR | Repair manual | Scag Power Equipment SCAG SCR Repair manual

Scag Power Equipment SCAG SCR Repair manual
PK
PW
PG/PE
PR
PJ
PC
P Series
Hydrostatic Pumps
Service and Repair Manual
BLN-52503
August, 2010
Table of Contents
Section
Page
Description and Operation.................................................................................................. 1
Introduction................................................................................................................................................... 1
General Description...................................................................................................................................... 1
External Features....................................................................................................................................... 2-7
PC Series............................................................................................................................................... 2
PG/PE Series......................................................................................................................................... 3
PJ Series................................................................................................................................................ 4
PK Series................................................................................................................................................ 5
PR Series............................................................................................................................................... 6
PW Series............................................................................................................................................... 7
Hydraulic Schematic.................................................................................................................................. 8-9
PC, PG, PE, PJ, PK and PR Series....................................................................................................... 8
PW Series............................................................................................................................................... 9
Graphical Schematic . ................................................................................................................................ 10
Technical Specifications...............................................................................................................................11
Product Identification.................................................................................................................................. 12
Safety................................................................................................................................... 13
Personal Safety........................................................................................................................................... 13
Tool Safety.................................................................................................................................................. 13
Work Area Safety........................................................................................................................................ 13
Servicing Safety.......................................................................................................................................... 13
Troubleshooting............................................................................................................ 14-15
P Series Flow Test Kit Instructions......................................................................................................... 16-17
Service and Maintenance............................................................................................. 18-20
External Maintenance................................................................................................................................. 18
Service and Maintenance Procedures........................................................................................................ 18
Fluids.......................................................................................................................................................... 18
Fluid Volume and Level............................................................................................................................... 19
Fluid Change............................................................................................................................................... 19
Filters.......................................................................................................................................................... 19
Purging Procedures.................................................................................................................................... 19
Return to Neutral Setting............................................................................................................................ 20
Repair........................................................................................................................... 21-126
PC Series Pump.................................................................................................................................... 21-36
PG/PE Series Pump.............................................................................................................................. 37-54
PJ Series Pump..................................................................................................................................... 55-72
PK Series Pump..................................................................................................................................... 73-90
PR Series Pump.................................................................................................................................. 91-108
PW Series Pump................................................................................................................................ 109-126
Glossary of Terms..................................................................................................... 127-128
FOREWORD
Headquartered in Sullivan, Illinois, Hydro-Gear
is a world leader in the design, manufacture, and
service of quality hydrostatic transaxles for the
lawn and garden industry. The mission of our
company is to be recognized by our customers
and the industry as a world-class supplier and
the quality leader in everything we do.
This Service and Repair Manual is designed to
provide information useful in servicing the
Hydro-Gear 6cc (0.37 cu in.) PC Series, the 10
cc (0.61 cu in.) PG Series, the 12 cc (0.73 cu
in.) PJ Series, the 16 cc (0.98 cu in.) PR Series,
and the 21 cc (1.28 cu in.) PW Series pumps.
Also included is a glossary of terms that are
frequently used throughout the industry and in
Hydro-Gear service publications. Understanding terminology is very important!
Some repair procedures require that the pump
be removed from the vehicle.
This is not a certification, test or study guide for
a certification test. If a technician is interested in
certification they should contact an agent
representing the OPEESA (Outdoor Power
Equipment and Engine Service Association)
(860-767-1770) or their Hydro-Gear Distributor. Many distributors will be hosting certification testing. These study guides will cover most
of the products and manufacturers in our industry.
For more information about Hydro-Gear or our
products, please contact your Central Service
Distributor, or call our Customer Service Department at (217) 728-2581.
It is necessary, and good shop practice, that your
service area be equipped with proper tools and
the mechanics to be supplied with the latest
information available. All repair procedures illustrated in this guide are suggested, but
preferred methods of repair.
iv
P Series
Section 1. Description and Operation
Introduction
The purpose of this manual is to provide information useful in servicing the Hydro-Gear PC, PG, PJ,
PK, PR and PW Pumps. This manual includes the
pump’s general descriptions, hydraulic schematics,
technical specifications, servicing and troubleshooting procedures for the pumps.
The P Series Pumps normally will not require
servicing during the life of the vehicle in which it
is installed. Should other servicing be required,
the exterior of the pump will need to be thoroughly
cleaned before beginning most procedures.
In some applications of the P Series Pumps, it is
desirable to move the machine for short distances at
low speeds without operating the engine. A screwtype bypass valve is utilized in the pumps to permit
movement of the machine. The bypass valve is fully
opened when unscrewed two (2) turns maximum.
The bypass valve allows oil to be routed from one
side of the pump/motor circuit to the other, thus
allowing the motor to turn with minimal resistance.
An increase in resistance will occur with movement
at higher speeds. The bypass valve must be fully
closed during normal operation.
General Description
The P Series Pumps can be combined with wheel
motors and other remotely located units. These
pumps provide an infinitely variable speed range
between zero and full displacement in both forward
and reverse modes of operation.
The P Series Pumps are of the axial piston design,
utilizing spherical nosed pistons. A compression
spring, located inside each piston, holds the nose
of the piston against a thrust bearing race.
The variable displacement pump features a cradle
swashplate with a direct-proportional displacement
control. Movement of the directional control shaft
produces a proportional swashplate movement and
a change in pump flow and/or direction.
WarnInG
actuating the bypass will result in the
loss of hydrostatic braking capacity. the
machine must be stationary, on a level
surface and in neutral when actuating the
bypass.
Additionally, some pumps may be equipped with
an Auxiliary Pump. The Auxiliary incorporates the
principles of the charge gerotor assembly and provides the capability of an external auxiliary flow for
an alternate hydraulic circuit to operate accessories
without loss of drive.
Reversing the direction of the angle of the swashplate reverses the flow of oil from the pump and thus
reverses the direction of motor output rotation.
A fixed displacement gerotor charge pump is
provided in P Series Pumps. Oil from an external
reservoir and filter is pumped into the closed loop
by a charge pump. Fluid not required to replenish
the closed loop flows either into the pump housing
through a cooling orifice, or back to the charge pump
inlet through the charge pressure relief valve.
Check or shock valves are included in the pump end
cap to control the makeup oil flow for the system.
The size and type of check valve can play an important role on the system pressure, response, and
amount of heat generated, due to the recirculation
of makeup oil flow. Shock valves are factory preset
pressure regulating check valves.
P Series
1
EXTERNAL FEATURES - PC Series
Figure 1. PC Pump with Standard Charge Pump
2
P Series
EXTERNAL FEATURES - PG Series
SAE “A” PAD
FLANGE STYLE
INLET
CHARGE
PRESSURE
DIAGNOSTIC
PORT
INPUT SHAFT
“A” and “B”
PORTS
STANDARD CHECK
VALVE OR SCR
CASE DRAIN
OPTION
CHARGE
COVER
STANDARD CHECK
VALVE OR SCR
BYPASS VALVE
TRUNNION
ARM
CASE DRAIN
OPTION
Figure 2. PG Pump With Standard Charge Pump
P Series
3
EXTERNAL FEATURES - PJ Series
Figure 3. PJ Pump with Standard Charge Pump
4
P Series
EXTERNAL FEATURES - PK Series
Figure 4. PK Pump With Standard Charge Pump
P Series
5
EXTERNAL FEATURES - PR Series
BYPASS
VALVE
SAE “A” PAD
FLANGE STYLE
TRUNNION ARM
INPUT SHAFT
INLET
CHARGE PRESSURE
DIAGNOSTIC PORT
“A” and “B” PORTS
SYSTEM CHECK VALVE
OR SHOCK VALVE
SYSTEM CHECK VALVE
OR SHOCK VALVE
CASE DRAIN
BYPASS VALVE
CHARGE
COVER
CASE DRAIN
Figure 4. PR Pump With Standard Charge Pump
6
P Series
EXTERNAL FEATURES - PW Series
SAE “B” PAD
FLANGE STYLE
TRUNNION ARM
“A” and
“B”
PORTS
INPUT SHAFT
BYPASS VALVE
STANDARD CHECK VALVE
OR SHOCK VALVE
CHARGE
PRESSURE
DIAGNOSTIC
PORT
CASE DRAIN
CHARGE
COVER
STANDARD CHECK VALVE
OR SHOCK VALVE
Figure 5. PW Pump With Standard Charge Pump
P Series
7
Hydraulic Schematic
System Check & Relief Valve Options
Orifice size Relief pressure (psi)
Relief pressure (bar)
No Bleed
.024 Bleed
.031 Bleed
.044 Bleed
Check ball
120
160
200
Check ball
1740
2320
2900
OR
OR
PORT “A”
SYSTEM
CHARGE
RELIEF
PORT “B”
CHARGE PUMP
INLET
CHARGE
DIAGNOSTIC
BYPASS VALVE
BLEED OPTIONS
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
Figure 6. PC, PG, PJ, PK and PR Pumps with Standard Charge Pump
System Check & Relief Valve Options
Orifice size Relief pressure (psi)
Relief pressure (bar)
No Bleed
.024 Bleed
.031 Bleed
.044 Bleed
Check ball
120
160
200
Check ball
1740
2320
2900
OR
AUXILIARY RETURN
OR
AUXILIARY DISCHARGE
PORT “A”
650 PSI
AUX RELIEF
SYSTEM
CHARGE
RELIEF
PORT “B”
CHARGE DIAGNOSTIC
CHARGE PUMP
INLET
BYPASS VALVE
BLEED OPTIONS:
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
Figure 7. PC, PG, PJ, PK and PR Pumps with AuxiliaryCharge Pump
8
P Series
Hydraulic Schematic
System Check & Relief Valve Options
Orifice size Relief pressure (psi)
Relief pressure (bar)
No Bleed
.024 Bleed
.031 Bleed
.044 Bleed
Check ball
120
160
200
Check ball
1740
2320
2900
OR
PORT “A”
PORT “B”
BYPASS VALVE
BLEED OPTIONS
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
CHARGE DIAGNOSTIC
CHARGE PUMP
INLET
Figure 8. PW Series Pump With Standard Charge Pump
System Check & Relief Valve Options
Orifice size Relief pressure (psi)
Relief pressure (bar)
No Bleed
.024 Bleed
.031 Bleed
.044 Bleed
Check ball
120
160
200
AUXILIARY
DISCHARGE
Check ball
1740
2320
2900
AUXILIARY
RETURN
OR
AUXILIARY
DISCHARGE
AUXILIARY
RETURN
PORT “A”
650 PSI
CHG
REL
PORT “B”
CHARGE PUMP
INLET
CHARGE
DIAGNOSTIC
BYPASS VALVE
BLEED OPTIONS
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
Figure 9. PW Series Pump With Auxiliary Charge Pump
P Series
9
GRAPHICAL Schematic
Figure 10. P Series Pump With Standard Charge Pump
Figures 10 represents a graphical schematic of the
P Series Pump with standard charge pump. Figure
10 provides a graphical illustration of the hydraulic
oil circuit.
The input shaft and pump cylinder block are turned
in one direction only by the engine/drive belt/pulley
combination or direct drive gear box.
The oil is drawn through an external filter by the
charge pump. The filter prevents contaminants
within the reservoir from entering into the charge
pump gerotor.
The charge pump supplies fluid to keep the closed
loop pressurized, preventing cavitation and providing cooling oil flow for the system.
The charge relief valve is used to maintain charge
at a predetermined pressure.
Output of the system oil flow is controlled by the
direction and amount that the swashplate is
angled. As the pump pistons compress, they force
oil into one of two passageways (“A” or “B”) in the
system hydraulic circuit. Oil is supplied externally
under pressure to an external load, (e.g., a vehicle
wheel motor).
10
As the angle of the pump swashplate is increased,
the amount of oil being pumped will increase and
cause a higher speed output of the wheel motor.
Reversing the angle of the swashplate will reverse
the direction of the oil flow. During the operation
of the pump, fluid is “lost” from the hydraulic loop
through leak paths designed into the product for
lubrication and cooling purposes (around pistons,
under the rotating cylinder block, etc.). This “lost”
fluid returns to the reservoir through the case drain.
This fluid must be made up in the loop. The charge
pump makes up this fluid loss.
The makeup flow is controlled (or directed) by the
system check valves. The check valves are used
to direct makeup fluid into the low pressure side
of the closed loop. Each check valve will either be
held open or closed, depending upon the direction
of the vehicle operation: Closed in a pressurized
system passage, open in a low pressure, “charged”
system passage.
P Series
TECHNICAL SPECIFICATIONS
Product Type
PC
PG
in3/rev
[cc/rev]
0.37
[6.1]
0.62 [10.2]
Input Speed
Maximum Unloaded
Minimum Loaded
rpm
rpm
3600
1800
3600
1800
System Operating Pressure
Continuous
Intermittent
Peak
psi
[bar]
psi
[bar]
psi
[bar]
750
[51]
1750
[120]
2500
[172]
1000
[70]
2100
[145]
3500
[240]
Displacement
Pump Performance
@2400 rpm/1000 psi
@3000 rpm/1000 psi
@3600 rpm/1000 psi gpm [l/min] 3.6 [13.6]
gpm [l/min] 4.5 [17.0]
gpm [l/min] 5.4 [20.4]
PJ/PK
PR
0.73 [12]
PW
0.97 [16]
1.33
[21.8]
3600
1800
3600
1800
3600
1800
1000
[70]
2100
[145]
3500
[240]
1250
[86]
2500
[172]
3750
[260]
1250
[86]
2500
[172]
3750
[260]
6.1 [23.1]
7.6 [28.8]
9.2 [34.8]
7.1 [26.8]
8.9 [33.6]
10.8 [40.8]
9.6 [36.3]
12 [45.4]
14.4 [54.5]
13.1 [49.6]
16.4 [62.1]
19.6 [74.2]
10 [0.7]
4 [0.3]
10 [0.7]
4 [0.3]
10 [0.7]
4 [0.3]
25 [1.7]
10 [0.7] 25 [1.7]
10 [0.7]
4
4
4
4
4
Case Pressure
Maximum @ Cold Start
Continuous - Max.
psi [bar]
psi [bar]
Inlet Vacuum
Maximum Continuous Inches Mercury
Charge Pump Displacement(s)
in3/rev
[cc/rev]
0.13
[2.1]
0.11/0.13
[1.9/2.1]
0.19
[3.2]
0.13/0.19
[2.1/3.2]
0.13/0.19
[2.1/3.2]
Auxiliary Pump Displacement
in3/rev
[cc/rev]
0.19
[3.2]
0.19
[3.2]
0.19
[3.2]
0.19
[3.2]
0.19
[3.2]
Auxiliary Pump Relief Setting
psi
[bar]
650
[45]
650
[45]
650
[45]
650
[45]
650
[45]
1.8 - 2.0 [6.8 - 7.6]
1.8 - 2.0 [6.8 - 7.6]
1.8 - 2.0 [6.8 - 7.6]
1.8 - 2.0
[6.8 - 7.6]
85
[9.6]
60
[6.8]
85
[9.6]
60
[6.8]
95
[10.7]
75
[8.5]
105
[11.9]
85
[9.6]
Auxiliary Pump Performance
@3200 rpm, 500 psi, 70 SUS
[13 Cst] oil, & 180°F
gpm 1.8 - 2.0
[l/min] [6.8 - 7.6] Control Torque Required to Stroke Pump
[Approximate - 20°External Stroke Angle]
lb-in / 1000 psi
[N-m / 70 bar]
lb-in / 500 psi
[N-m / 35 bar]
Pump Oil Temperature
Maximum Intermittent (hottest point)
Normal Operating Range
75
[8.5]
55
[6.2]
°F
230
[°C]
[110]
°F -10 to 200 [°C] [-23 to 93]
230
[110]
-10 to 200
[-23 to 93]
230
230
[110]
[110]
-10 to 200 -10 to 200 [-23 to 93] [-23 to 93] 230
[110]
-10 to 200
[-23 to 93]
Fluid Viscosity Limits @ 230°F [110°C]
Optimum
SUS [cSt]
Minimum
SUS [cSt]
70 [13]
55 [9]
70 [13]
55 [9]
70 [13]
55 [9]
70 [13]
55 [9]
70 [13]
55 [9]
Weight of Unit
lbs [kg]
7 [3.2]
8 [3.6] 12.65 [5.7] 12 [5.4] 14 [6.3]
micron
25
25
25
25
25
Inlet Filtration Requirement
Nominal
Table 1: P Series Pump Technical Specifications
P Series
11
PRODUCT IDENTIFICATION
The label in Figure 11 is located on the pump housing. It identifies the model and configuration of the
pump.
HYDRO-GEAR
model number
PC-AGCC-MV1X-XXXX
4 244 P1 0192
MADE IN U.S.A.
year Built
date
(Julian - day of year)
Serial number
(unique number for that model - for that day)
type of Product and Build Information
Figure 11. P Series Pump Configuration Label
12
P Series
Section 2. Safety
This symbol points out important safety
instructions which, if not followed, could endanger the personal safety and/or property
of yourself and others. Read and follow all instructions in this manual before attempting maintenance
on your P Series Pump. When you see this symbol
- HEED ITS WARNING.
Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the appropriate safety equipment, such as eye and hearing
protection, and safety-toe and slip-proof shoes.
Never use compressed air to clean debris from
yourself or your clothing.
TOOL safety
Warning
potential for serious injury
Inattention to proper safety, operation, or
maintenance procedures could result in
personal injury, or damage to the equipment. Before servicing or repairing the P
Series Pump, read fully and understand
the safety precautions described in this
section.
Personal safety
Certain safety precautions must be observed while
servicing or repairing the P Series Pump. This section addresses some of these precautions but must
not be considered an all-inclusive source on safety
information. This section is to be used in conjunction with all other safety material which may apply,
such as:
• Other manuals pertaining to this machine
• Local and shop safety rules and codes
• Governmental safety laws and regulations
Be sure that you know and understand the equipment and the hazards associated with it. Do not
place speed above safety.
Notify your supervisor whenever you feel there is
any hazard involving the equipment or the performance of your job.
Use the proper tools and equipment for the task.
Inspect each tool before use and replace any tool
that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure it is
well lit, extra tools are put away, trash and refuse
are in the proper containers, and dirt or debris
have been removed from the working areas of the
machine.
The floor should be clean and dry, and all extension
cords or similar trip hazards should be removed.
Servicing Safety
Certain procedures may require the vehicle to be
disabled in order to prevent possible injury to the
servicing technician and/or bystanders.
The loss of hydrostatic drive line power may result
in the loss of hydrostatic braking capability.
Some cleaning solvents are flammable. Use only
approved cleaning materials: Do not use explosive
or flammable liquids to clean the equipment.
To avoid possible fire, do not use cleaning solvents
in an area where a source of ignition may be present.
Discard used cleaning material in the appropriate
containers.
Never allow untrained or unauthorized personnel to
service or repair the equipment.
P Series
13
Section 3. Troubleshooting
WARNING
Do not attempt any servicing or adjustments with the engine running.
Use extreme caution while inspecting
the drive belt assembly and all vehicle
linkage!
Follow all safety procedures outlined in
the vehicle owner’s manual!
In many cases, problems with the P Series Pump
are not related to a defective pump but are caused
by slipping drive belts, partially engaged bypass
valves, and loose or damaged control linkages. Be
sure to perform all operational checks and adjustments outlined in Section 3 before assuming the
pump is malfunctioning. Table 2 below provides
a troubleshooting checklist to help determine the
cause of operational problems.
Possible Cause
Corrective Action
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated
Refer to vehicle manufacturer suggested pressure
Control linkage bent, loose or out of adjustment
Repair, adjust or replace vehicle linkage
Bypass loose
Tighten pump bypass per External Maintenance
step 9, page 17
Inlet Leak
Check all external lines and connections to pump
inlet
UNIT IS NOISY
Excessive input speed
Adjust input speed above 1800 rpm and below
3600 rpm
Oil level low or contaminated oil
Fill reservoir to proper level or change oil
Excessive loading
Reduce vehicle load
Air trapped in hydraulic system
Purge hydraulic system per Purging Procedures
on page 18
Bypass loose
Tighten pump bypass per External Maintenance
step 9, page 17
Inlet leak, line or filter partially blocked or
Check all external lines and connections
and filter
damaged
to pump inlet
Table 2. Pump Troubleshooting Checklist
14
P Series
Possible Cause
Corrective Action
UNIT HAS NO/LOW POWER
Engine speed low
Adjust to correct rpm setting
Control linkage bent, loose or out of adjustment
Repair or replace vehicle linkage
Drive belt slipping or pulley damaged
Repair or replace drive belt or pulley
Oil level low or contaminated oil
Fill reservoir to proper level or change oil
Excessive loading
Reduce vehicle load
Bypass loose
Tighten pump bypass per External Maintenance
step 9, page 17
Air trapped in hydraulic system
Purge hydraulic system per Purging Procedures
on page 18
Inlet leak
Check all external lines and connections to pump
inlet
Inlet filter clogged
Replace inlet filter
Suspected internal damage
Check pump by performing Flow Test on page 15
UNIT OPERATING HOT
Debris buildup
Remove debris from pump and fan
Cooling fan or heat exchanger damaged
Repair or replace cooling fan or heat exchanger
Oil level low or contaminated oil
Fill reservoir to proper level or change oil
Excessive loading
Reduce vehicle load
Air trapped in hydraulic system
Purge hydraulic system per Purging Procedures
on page 18
Inlet leak
Check all external lines and connections to pump
inlet
PUMP LEAKS OIL
Damaged seals and gaskets
Remove debris, replace seals
Air trapped in hydraulic system
Purge hydraulic system per Purging Procedures
on page 18
P Series
15
P SERIES FLOW TEST KIT INSTRUCTIONS
BLN-51334 July 2010
(This Instruction Sheet supersedes all previous flow testing instructions)
Description: P Series Flow Test Kit (Part Number 70661)
(Part Number 70661 Supersedes Part Numbers 70511 and BB-76810)
Purpose: The design purpose of the P Series Flow Test Kit is to allow the customer to isolate the pump from the
wheel motor and determine if the pump is acceptable. The following information can be used to install and test the
pump by simulating a wheel motor load.
WARNING
WARNING
Certain procedures require the vehicle engine
to be operated and the vehicle to be raised off
of the ground. To prevent possible injury to the
servicing technician and/or bystanders, insure
the vehicle is properly secured.
Do not attempt any adjustments with the engine
running. Use extreme caution while working in
or around all vehicle linkage! High temperatures
can be generated. Follow all safety procedures
outlined in the vehicle owner’s manual!
INSTALLATION AND TESTING PROCEDURES:
1. Disconnect the system hoses at the wheel motor, or system hoses from the pump and connect the
P Series Flow Test Kit. (Special care should be taken to prevent contamination debris from entering
pump or wheel motor system ports)
Note: Using the Bi-Directional Flow Test Kit, determination of directional flow is not necessary. The flow
meter may be connected in either direction into the forward and reverse high pressure system lines.
CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the
vehicle’s high pressure system lines. Failure to perform this properly could result in bodily injury.
TESTING PROCEDURES:
1. Raise the drive tires off of the ground. Block the remaining tires on the ground to prevent accidental
vehicle movement.
2. Open the restriction valve all the way.
3. Make certain all external pump directional control stops are removed or backed off on the vehicle
linkage to obtain full pump directional control arm travel.
4. Start the engine and engage the drive pulley if necessary.
5. Bring the engine to maximum operating speed.
(This should not exceed 3600 rpm input speed on the PC, PL, PG, PE, PK and PJ Series Pumps)
(This should not exceed 3400 rpm input speed on the PR)
(This should not exceed 2800 rpm input speed when testing the PW)
Engine speed adjustment may be necessary to obtain 2800 rpm.
CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the
vehicle’s high pressure system lines. Failure to perform this properly could result in bodily injury.
6. With the directional control lever (on the vehicle) for the pump being tested, move the control arm in
full forward motion. (It may be necessary to lock the control arm into full forward position to prevent
false readings).
7. Operate without any load for approximately 30 seconds to 1 minutes. This allows the system oil temperature to rise.
16
P Series
Note: Raising the system oil temperature will make a difference in the readings you receive. It has been
determined that to complete this test accurately, the oil temperature must be near system operating temperatures.
Suggested temperature range is 160°- 210°F (71.1° - 98.9°C).
8. On the PC, PG, PE, PJ, PK, PL, PR and PW, tighten the flow meter restriction valve until the gauge reads 300
psi (21bar). Record the flow reading on the Bi-Directional Flow Meter.
9. Increase the pressure to 1100 PSI (76 bar) for all models (PC, PG, PJ, PK, PL, PR and PW). Record the flow
reading on the Bi-Directional Flow Meter.
10. The acceptable gpm “flow droop” or (difference) is:
PC
1.0 gpm (3.7 l/min)
PG/PL/PE
1.5 gpm (5.6 l/min)
PJ/PK
2.0 gpm (7.6 l/min)
PR
2.5 gpm (9.4 l/min)
PW
2.5 gpm (9.4 l/min)
If the difference exceeds these values the pump would not be operating efficiently and should be repaired or
replaced.
TEST EXAMPLE: PG/PL
300 psi (21 bar) reading
7 gpm (26 l/min) (1st reading)
1100 PSI (76 bar) reading
3 gpm (11 l/min) (2nd reading)
(PG/PL/PE)
300 psi (21 bar) reading
1100 psi (76 bar) reading
7 gpm (26 l/min) (1st reading)
-3 gpm (11 l/min) (2nd reading)
4 gpm (15 l/min) (the difference)
P Series
Subtract the 1st reading from the 2nd.
(In this example, 4 gpm difference would
indicate further pump examination).
17
Section 4. Service and Maintenance
NOTE: Any servicing dealer attempting a
warranty repair must have prior approval
before conducting maintenance of a
Hydro-Gear product, unless the servicing
dealer is a current authorized Hydro-Gear
Service Center.
External Maintenance
Regular external maintenance of a P Series Pump
should include the following:
1.Check the vehicle operator’s manual for
the recommended load ratings. Insure the
current application does not exceed load
rating.
2. Check fluid level in reservoir in accordance with
vehicle manufacturer’s recommendations.
NOTE: After the oil has been drained
and maintenance has been performed,
clean oil should be poured directly into
the pump inlet and high pressure ports
prior to plumbing connections and pump
start-up.
3. Inspect the vehicle drive belt, idler pulley(s), and
idler spring(s). Insure that belt slippage is not
causing low input rpm to the pump.
4. Inspect all external plumbing for possible leaks
or loose fittings. An air leak may be difficult to
detect on the “suction side” or inlet line to the
pump. Refer to Purging Procedures page 18.
5. Insure correct inlet filter(s) has been installed
in accordance with the vehicle manufacturer
recommendations.
6. Insure the reservoir is free of contaminants and
is properly vented.
7. Inspect the P Series Pump cooling fan (if
applicable) for broken or distorted blades and
remove any obstructions (grass clippings,
leaves or dirt). Inspect oil cooler (if applicable)
for damaged fins and debris.
18
8. Inspect the vehicle control linkage to the
directional control arm on the P Series Pump.
Also, insure the control arm is securely fastened
to the trunnion arm.
9. Inspect the bypass on the P Series Pump to
insure it is properly engaged for operation. If
the bypass is not fully engaged (rotated fully
clockwise) it will not function properly. For
vehicle movement without engine power, the
bypass may be backed out (2) turns maximum.
This is only recommended for movement of
short distances at low speeds.
Warning
Loosening the bypass will result in loss
of hydraulic braking capability.
Service and Maintenance
Procedures
NOTE: Damage to P Series Pumps may
result from external or internal contamination, heat from excess debris or lack
of lubrication and over-pressurization
of the hydrostatic system. Follow guidelines established in this manual and the
vehicle manufacturer’s recommendations.
All the service procedures presented on the following pages can be performed while the P Series
Pump is mounted on the vehicle. Any servicing
beyond those presented in this section must be
performed after the pump has been removed from
the vehicle.
Fluids
The fluids used in Hydro-Gear products have been
carefully selected, and only equivalent, or better
products should be substituted.
Typically, an engine oil with a minimum rating of 55
SUS (9.0 cSt) at 230° F (110° C) maximum operating temperature and an API classification of SJ/CD
is allowed. Refer to the vehicle manufacturer for
recommended oil.
P Series
Fluid Volume and Level
Certain situations may require additional fluid to
be added or even replaced. Refer to the vehicle
manufacturer’s recommendations for the proper fill
location and level. After maintenance or oil change,
follow purging procedures below and check the
fluid level once the unit has been operated for approximately 1 minute.
FLUID CHANGE
In the event of oil contamination or degradation,
oil addition or change may alleviate certain performance problems. Refer to the vehicle manufacturer’s recommended oil change frequency. Refer to
purging procedures below after changing fluids.
FILTERS
An inlet filter is required to insure that only clean fluid
enters the system. Refer to the vehicle manufacture
for approved filter replacement.
Purging Procedures
Due to the effects air has on efficiency in hydrostatic
drive applications, it is critical that air is removed or
purged from the system.
These purge procedures must be preformed anytime a hydrostatic system has been opened for
maintenance or repair, or if any additional oil has
been added to the system.
Air creates inefficiency because it has compression and expansion rates that are higher than that
of oil.
Air trapped in the oil may cause the following
symptoms:
1. Noisy operation.
2. Lack of power or drive after short-term
operation.
3. High operation temperature and excessive
expansion of oil.
WARNING
POTENTIAL FOR serious INJURY
Certain procedures require the vehicle
engine to be operated and the vehicle to
be raised off of the ground. To prevent
possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured.
1. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to 6
times). As air is purged from the unit, the oil level
in the reservoir will drop.
2. With the bypass valve closed and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to
6 times). Check the oil level, and add oil as
required after stopping engine.
3. It may be necessary to repeat steps 1 and
2 until all the air is completely purged from
the system. When the P Series Pump moves
forward and reverse at normal speed and the
reservoir oil remains at a constant level, purging
is complete.
Cleanliness is a key factor in the successful repair of
pumps. Thoroughly clean all exposed surfaces prior
to any type of maintenance. Cleaning of all parts
by using a solvent wash and air drying is usually
adequate. As with any precision equipment, all parts
must be kept free of foreign material and chemicals.
Protect all exposed sealing areas and open cavities
from damage and foreign material.
Upon removal, all seals, O-rings, and gaskets
should be replaced. During installation, lightly lubricate all seals, O-rings, and gaskets with clean
petroleum jelly prior to assembly. Also protect the
inner diameter of seals by covering the shaft machined features with plastic wrap or equivalent.
Before starting, make sure the reservoir is at the
proper oil level. If it is not, fill to the vehicle manufacturer’s specifications.
The following procedures should be performed
with the vehicle drive wheels off the ground, then
repeated under normal operating conditions.
P Series
19
RETURN TO NEUTRAL SETTING
Warning
WARNING
potential for serious injury
Do not attempt any servicing or adjustments with the engine running.
Use extreme caution while inspecting
the drive belt assembly and all vehicle
linkage!
Inattention to proper safety, operation, or
maintenance procedures could result in
personal injury, or damage to the equipment. Before servicing or repairing the P
Series Pump, fully read and understand
the safety precautions described in this
manual.
The return to neutral mechanism on the pump is
designed to set the directional control into a neutral
position when the operator releases the vehicle
hand control. Follow the procedures below to
properly adjust the return to neutral mechanism on
the pump:
1. Confirm the pump is in the operating mode
(bypass disengaged). Raise the vehicle’s drive
tires off the ground to allow free rotation.
2. Remove the Original Equipment Manufacturer’s
(OEM’s) control linkage at the control arm.
3. Start the engine and increase the throttle to full
engine speed.
Follow all safety procedures outlined in
the vehicle owner’s manual.
4. Check for axle rotation. If the axle does not
rotate, go to Step 5. If the axle rotates, go to
Step 6.
5. Stop the vehicle’s engine. Reattach and adjust
the vehicle’s linkage according to the vehicle
owner’s manual.
6. Note the axle directional movement. Stop the vehicle engine. Loosen the RTN adjustment screw
until the control arm can be rotated. Rotate the
control arm in the proper direction until neutral is
obtained (motor shaft does not rotate). Tighten
the RTN adjustment screw. Recheck according
to steps 3 and 4. Refer to Figure 12.
RTN Adjusting Screw
Speed & Direction
Control Arm
Figure 17. P Series Pump RTN Adjustment
20
P Series
REPAIR - PC SERIES PUMP
Repair - PC Series Pump ..................................................................................................... 21-36
How to Use This Manual .............................................................................................................. 21
General Instructions .................................................................................................................... 21
Tools and Torques ....................................................................................................................... 22
Return to Neutral Linkage ............................................................................................................ 23
Standard Control Arm Linkage ..................................................................................................... 24
Fan Assembly .............................................................................................................................. 24
Input Shaft Seal ........................................................................................................................... 25
Trunnion Arm Seal ....................................................................................................................... 25
Shock Valves ............................................................................................................................... 26
Bypass ........................................................................................................................................ 26
Charge Pump-Standard or Thru Shaft......................................................................................... 27
Auxiliary Pump ............................................................................................................................. 28
End Cap ...................................................................................................................................... 29
Cylinder Block ............................................................................................................................. 30
Block Spring and Thrust Bearings ............................................................................................... 31
Swashplate and Cradle Bearings ................................................................................................ 31
Input Shaft ................................................................................................................................... 32
Trunnion Arm ............................................................................................................................... 33
Parts List ............................................................................................................................... 34-35
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded view
showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 34 and 35
for part names and descriptions. A
complete exploded view and item list of the pump is
provided at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each pump.
These seals can be replaced without major
disassembly of the unit. However, replacement of
these seals generally requires removal of the pump
from the machine. Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly clean
all exposed surfaces prior to any type of
maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with
any precision equipment, all parts must be kept free
of foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PC Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
21
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
7/16-inch Socket
Torque Wrench
1/2-Inch Socket
Scribe, Paint Pen, or Marker
11/16-Inch Socket
Seal Hook with a Magnet
10-mm Socket
Flat Blade Screwdriver
Combination Wrenches
Pliers
7/16 Inch
Internal Snap Ring
1/2 Inch
Allen Wrenches
11/16 Inch
1/8 inch
10 mm
1/4 inch
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
Fan Nut, Hex Lock 5/16-24 UNF
4, End Cap/Adapter Plate Bolts
10, Cap Screw
15, Bypass Valve
42A, 42B, Shock Valves/Check Plugs
44, System Charge Relief Kit (Aux Chg)
45, Aux Relief Valve Kit
56, Diagnostic Plug
66, Filter Cover Plug
67, Filter Cover
103, Screw 5/16 x .875
106, Nut, Hex Lock 5/16-24 UNF
164, Plug, Metal 7/16-20
200-250 lb-in (22.6-28.2 Nm)
370-470 lb-in (41.8-53.1 Nm)
200-250 lb-in (22.6-28.2 Nm)
120-160 lb-in (13.5-18.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
110-130 lb-in (12.4-14.7 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
84-120 lb-in (9.4-13.5 Nm)
55-85 lb-in (6.2-9.6 Nm)
200-275 lb-in (22.6-31.1 Nm)
200-240 lb-in (22.6-27.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
84-120 lb-in (9.4-13.5 Nm)
Table 2. PC Pump Torque Values
22
PC Series
PC SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Refer to Figure 1.
Inspection
Prior to disassembly, note the position of the scissor
arm brackets and the tab on the outer control arm
bracket.
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
2.
Disassembly
Inspect bushing (101) and all other linkage parts
for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
Assembly
1. Loosen (but do not remove) the nut (106).
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
2. Install the outer control arm bracket, washer
(105) and bushing (101).
3.
Remove the spring (102), nut (106) washer (104)
and outer scissor control arm bracket.
4. Remove bushing (101), washer (105), and the
inner scissor control arm bracket.
5.
Remove the outer control arm bracket, bolt
(103), washer (104) and the inner return arm
bracket.
1. Install the inner return arm bracket, washer (104)
and bolt (103).
3. Install the inner scissor control arm bracket,
washer (105), and outer scissor control arm
bracket.
4. Install washer (104), and nut (106). Tighten to
the correct torque value. See page 22.
5. Install the spring (102).
49
104
103
37
105
101
105
104
106
110
102
Figure 1. Return to Neutral Assembly
PC Series
23
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the nut (106), washer (104) and bushing
(101).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket.
3. Remove bolt (103), washer (104) and the inner
control arm bracket.
2. Remove the nut (106) and fan assembly (90).
3. Remove the bolts (10) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2.
Assembly
Inspect bushing (101) and all other linkage parts
for damage, corrosion or wear.
1. Install the inner control arm bracket, washer
(104) and bolt (103).
1. To install the mounting bracket (209), align and
insert the bolts (10) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (10) per table 2, page
22.
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. Install the fan and washer assembly onto the
shaft.
2. Install the outer control arm bracket, bushing
(101), washer (104) and nut (106). Tighten to
the correct torque value. See page 22.
3.
Assembly
Install the nut (106) and tighten per table 2, page
22.
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
209
49
(2X) 10
104
103
90
104
37
101
106
106
110
210
Figure 2. Standard Control Arm
Figure 3. Fan Assembly
24
PC Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION ARM
SEAL
Refer to Figure 4.
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (22) from housing.
1. Remove the RTN assembly or control arm.
2. Remove lip seal (20). Care must be taken to
prevent damage to the housing bore, shaft
sealing surface, or bearing. Once removed, the
seal is not reusable.
2. Remove the retainer and lip seal (49) from the
housing. Care must be taken to prevent damage
to the housing trunnion bore, trunnion arm and
sealing surface. Once removed the retainer and
lip seal are not reusable.
Inspection
With seal removed inspect the spacer (21) and
housing (1) bore for damage, corrosion or wear.
Assembly
1. Lubricate the new lip seal (20) inside diameter
with petroleum jelly.
2. Wrap the input shaft (18) with plastic wrap to
prevent damage to the inner surface of the lip
seal (20).
3. Slide spacer (21) and seal (20) over shaft (18)
so that lettering on the seal faces out.
4. Press the lip seal (20) into the housing bore.
Insure the lip seal (20), shaft (18) or housing (1)
bore do not become damaged. Remove the
plastic wrap.
5. Install the retaining ring (22) into the housing (1)
bore groove. Refer to Figure 4.
Inspection
With the lip seal (49) removed, inspect the area for
corrosion and wear. Inspect the trunnion bore area
sealing surface for damage or wear.
Assembly
1. Lubricate the new lip seal (49) inside diameter
with petroleum jelly.
2. Wrap the trunnion arm with plastic wrap to
prevent damage to the inner surface of the lip
seal (49).
3. Slide the lip seal (49) over the trunnion arm so that
the lettering on the seal (49) faces out.
4. Press the lip seal (49) into the housing bore.
Insure the seal (49), trunnion arm, and housing
bore do not become damaged. Remove plastic
wrap.
5. Install the retainer from (49) over the trunnion
arm on top of the lip seal. Press into the trunnion
seal bore in the housing until the retainer mates
against the trunnion seal.
6. Install the RTN assembly or control arm.
Figure 4. PC Pump Input Shaft Seal
Figure 5. Trunnion Arm Seal
PC Series
25
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF SHOCK VALVES
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF THE BYPASS
Refer to Figure 6.
Refer to Figure 7.
Perform disassembly, inspection and assembly on
shock valve one side at a time. Some units vary in
“A” side to “B” side configuration.
Disassembly
Disassembly
1. Remove the shock valve (42) with an 11/16-inch
wrench.
1. Loosen the bypass valve (15) using a 7/16-inch
wrench.
2. Remove the bypass (15) from the end cap.
Inspection
2. Remove the shock valve spring and the shock
valve from the end cap.
1. Inspect the bypass O-rings and mating seats in
the end cap for damage or foreign material.
Inspection
2. If damaged or worn, replace bypass (15).
Inspect the shock valve (42) and mating seat in the
end cap for damage or foreign material.
Assembly
Assembly
1. Position the pump so the shock valve port is
horizontal.
2. Insert the shock valve spring and shock valve
as one assembly into the check plug port. Tighten
to the correct torque value. See Table 2, page
22 (Torque Values).
1. Position the pump so the bypass port is
horizontal.
2. Insert the bypass (15) into the bypass port of
the end cap. Tighten to the correct torque value.
See Table 2, page 22 (Torque Values).
3. Repeat disassembly, inspection and assembly
for the opposite port.
Figure 7. PC Pump Bypass
Figure 6. PC Pump Shock Valves
26
PC Series
REMOVAL, INSPECTION AND
ASSEMBLY OF THE STANDARD OR
THRU SHAFT CHARGE PUMP
NOTE: For thru shaft charge pump assembly,
follow steps 1 thru 8. For standard charge pump,
follow steps 3 thru 8.
Refer to Figure 8.
Assembly
Disassembly
1.
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Press the shaft seal into the charge cover. Be
careful not to damage the shaft seal or charge
cover bore.
2. Using a 1/2-inch wrench, loosen the charge
pump cover bolts (10) from the end cap (2). While
holding the charge cover (6) in place, remove
the charge cover bolts (10).
3. Position the pump with the input shaft down, and
the end cap (2) horizontal. Place the charge ball
(44) in the end cap (2) charge passage so the
ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
ball.
3. Remove the charge cover, O-ring (8) and
gerotor items (7). Carefully check for and remove
the charge spring and charge ball (44).
4. For thru shaft charge pump, remove the shaft
seal.
Inspection
1. Inspect the charge cover O-ring (8) and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap (2) for
damage or foreign material.
2. Inspect the charge cover bore for damage
corrosion or wear.
NOTE: If the end cap (2) is to be removed from the
housing, do not assemble the charge pump (6)
until the end cap is installed on the housing.
Lubricate the new shaft seal with petroleum jelly.
4. Insert the inner gerotor over input shaft (18).
5. Align the outer gerotor to fit over the inner gerotor.
6. Insert the O-ring (8) into the groove in the charge
cover.
7. Position the charge cover and O-ring with the
aligning mark on the end cap. Place the charge
cover and O-ring as one piece over the charge
spring and gerotor assembly. Insure the spring
fits into the charge cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 22 (Torque
Values).
8
44
7
THRU SHAFT
6
18
2
8
(2X) 10
7
STANDARD
6
(2X) 10
Figure 8. PC Pump Standard or Thru Shaft Charge Pump
PC Series
27
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 9.
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
22.
Assembly
Disassembly
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump (6), charge pump
(7) and end cap (2) for alignment at assembly.
2. Install the poppet, spring and cap as one
assembly (44) into the charge relief port.
Tighten to the correct torque value. See page
22.
2. Use a 10 mm wrench to loosen the auxiliary
pump bolts (10) from the end cap (2). While
holding the auxiliary pump in place, remove the
bolts (10).
3. Install the filter (54) and O-ring into the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
3. Remove the auxiliary pump, gasket, O-ring (8)
and charge pump (7). While removing the
charge pump, be sure to retain the spring and
ball (44A) housed in the end cap (2).
4.
Remove the plug (66) from the filter cover (67).
5.
Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the pump.
4. Lay the PC pump (input shaft down), so the
end cap is horizontal. Install the O-ring (8) into
the charge pump (7).
5. Install the gasket onto the auxiliary pump.
6.
6. Make sure that the ball and spring (44A) are
seated in the end cap (2), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
fully engages the alignment pins (69).
Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44)
and auxiliary relief valve assembly (45) from the
auxiliary pump.
7. Align and insert the bolts (10) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (10)
per table, page 22.
Inspection
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
2.
Inspect all O-rings, gasket and mounting seats.
44A
6
8
7
44
(2X) 69
8
18
2
45
67
164
54
66
(2X) 10
Figure 9. PC Series Auxiliary Pump
28
PC Series
3. Replace the housing gasket (5) with a new
gasket before assembly.
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP
Assembly
Refer to Figure 10.
1. Install housing gasket (5) into housing gasket
seat of housing (1).
Disassembly
1. Remove charge pump. (See page 27).
2. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly.
3. Hold the end cap (2) in place and remove the
four end cap bolts (4).
4. Slowly remove the end cap (2).
5. Remove housing gasket (5).
Inspection
2. Lubricate the mating surface of the cylinder
block (31) to end cap (2) with clean oil prior to
installation.
3. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (2)
verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten to the correct
torque value. See Table 2, page 22 (Torque
Values)
4. Install the charge pump. (See page 27).
1. Inspect the end cap (2) body for damage, nicks
or unusual wear patterns. Replace if necessary.
2. Inspect the running surface (side that contacts
the cylinder block) (31). The running surface
may show evidence of minor abrasive rings, this
is normal.
Grooving in the plate, or material transfer that is
evident when the surface is checked by dragging
a fingernail across it, would be cause for
replacement of the end cap (2).
31
1
5
2
4
Figure 10. PC Pump End Cap
PC Series
29
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Refer to Figure 11.
Disassembly
1. Remove charge pump. (See page 27).
2. Remove end cap. (See page 29).
3. Tilt the pump on its side and drain remaining oil.
Lift out the cylinder block assembly (25).
2. Install piston seats into the end of the pistons.
3. Install springs into the pistons.
4. Install each piston, spring and seat assembly into
the cylinder block.
NOTE: To assist in cylinder block installation, a rubber band can be placed
around all of the pistons to hold them
in position.
After the cylinder block is installed, cut
the rubber band and remove it from the
housing.
4. Remove the pistons, springs and piston seats.
Inspection
1.
Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This will be normal
wear. If grooved or smeared, replace with a new
cylinder block assembly.
2. Inspect the piston springs for distortion or breaks.
If necessary, replace with a new cylinder block
kit.
3. Inspect the piston seats. Residual oil may cause
these to remain stuck to the inside of the pistons.
Assembly
5. With the pump housing tilted on its side, install
the cylinder block assembly (25) with pistons
contacting the thrust bearing.
NOTE: To check if the cylinder block
assembly is installed correctly, position
the pump housing vertically and support the housing at the mounting flange.
Push down on the cylinder block. The
cylinder block must move up and down
freely. If it does not, remove the cylinder block assembly and reinstall.
6. Install the end cap. (See page 29).
7. Install the charge pump. (See page 27).
1. Apply a thin layer of clean oil to the pistons and
springs.
Figure 11. PC Pump Cylinder Block Assembly
30
PC Series
REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING AND
THRUST BEARING
REMOVAL, INSPECTION AND
ASSEMBLY OF SWASHPLATE AND
CRADLE BEARINGS
Refer to Figure 12.
Refer to Figure 13.
Disassembly
Disassembly
1. Remove the block spring (29).
Remove the swashplate (32).
2. Remove the thrust bearing and races (34).
Inspection
Inspection
1. Inspect the running surface of the bearing pocket
of swashplate (32) for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This is normal wear.
Inspect the cradle bearing side of the swashplate
(32) for damage. Replace if necessary.
1. Inspect and replace the block spring (29) if it is
distorted or broken.
2. Inspect the running surface of the bearing races
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor
abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Assembly
1. Install thrust bearing and race assembly
(34).
2. Install block spring (29).
2. Inspect the cradle bearings attached to the inside
of the housing (1) for normal wear patterns and
placement, and insure they are staked securely
in place. If the bearings are damaged, replace
housing (1).
NOTE: The cradle bearings will have discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (32) by holding trunnion arm’s
slot guide (38) with a flat tip screwdriver. Use
the screwdriver to hold the slot guide in place
while positioning the swashplate (32) onto the
cradle bearing in the housing (1).
2. Rotate trunnion arm (37) to verify that the
swashplate moves freely.
Figure 12. PC Pump Block Spring and
Thrust Bearing
Figure 13. PC Pump Swashplate and
Cradle Bearings
PC Series
31
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
Refer to Figure 14.
Assembly
NOTE: If trunnion arm is to be removed,
do not assemble input shaft until the trunnion arm is installed.
Disassembly
NOTE: During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. Remove the retaining ring (22).
2. Remove the lip seal (20).
3. Remove the spacer (21).
3. Remove the shaft (18) and bearing (19) assembly
(18) from the pump.
Inspection
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace
shaft assembly if necessary.
2. Inspect the bearing (19) for evidence of scoring,
corrosion, or damage. If the bearing must be
replaced, remove the retaining ring (23) and use
a press or bearing puller to remove the bearing.
3. Inspect and replace the spacer (21) if it is bent
or broken.
4. Inspect and replace the retaining ring (22) if it is
bent or broken.
1. If removed, press bearing (19) onto shaft (18)
tight against the shoulder of the shaft. Install
retaining ring (23) onto the shaft (18).
2. Install input shaft assembly (18) into the housing
(1) bore. Light tapping with a rubber mallet may
be necessary on the input shaft (18) once the
bearing is aligned with the housing (1) bore.
Verify that the shaft rotates smoothly.
3. Install spacer (21).
4. Install new lip seal (20) with the flat side of the
seal toward the outside of the pump.
5. Remove the plastic wrap.
6. Install retaining ring (22).
NOTE: Upon removal, all seals, O-rings
and gaskets should be replaced.
Figure 14. PC Pump Input Shaft
32
PC Series
REMOVAL, INSPECTION AND
INSTALLATION OF TRUNNION ARM
Refer to Figure 15.
Disassembly
1. Remove the slot guide (38).
2. Remove and discard the trunnion seal retainer
and seal (49).
3. Remove the trunnion arm (37).
Assembly
1. Install the trunnion arm (37) into the housing (1)
bore. Rotate the trunnion arm to verify free
movement.
NOTE: During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of the
seals by covering the shaft with plastic
wrap. Remove the plastic wrap after the
seal is installed.
Inspection
NOTE: Upon removal, all seals, O-rings
and gaskets should be replaced.
1. Inspect the trunnion arm (37) for wear or
damage. Replace the trunnion arm if necessary.
2. Check for excessive play between trunnion arm
(37) and housing (1). Replace housing if
necessary.
2. Install a new seal and seal retainer (49).
3. Install slot guide (38).
4. To completely assemble the pump, refer to the
assembly steps on pages 23-33. Begin with the
trunnion arm assembly steps listed on page 33
and complete the assembly steps in reverse
order working toward the front of the manual.
1
38
49
37
Figure 15. PC Pump Trunnion Arm
PC Series
33
34
Figure 16. PC Pump
Kit Number
BOXES INDICATE ITEMS INCLUDED IN KITS.
PC Series
ITEM LIST - PC SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No. Description
No.
Description
1
2
4
5
6
44
Charge Relief Valve Kit (1/4 in. Plastic
Ball and 50654 Spring)
Auxiliary Relief Valve Kit
Trunnion Seal/Retainer Kit
Filter Kit
Plate, Adapter (Gear AA)
Plug, 5/16 - 24
Plug
Filter Cover
Pin, Straight Headless
Pin, Straight Headless
Fan Kit
Overhaul Seal Kit
Spacer, Return
Spring, Extension
Screw, 5/16 x 0.875 in. (PATCH)
Washer, 0.34 x 0.88 x 0.06 in.
Washer, Nylon
Nut, Hex Lock, 5/16 - 24 UNF
Return-to-Neutral Kit, Std.
Return-to-Neutral Kit, CW Scissor
Return-to-Neutral Kit, CCC Scissor
Return-to-Neutral Kit,
Shroud Bracket
Shroud
7
8
10
15
18
19
20
21
22
23
25
29
32
34
37
38
42
Housing Kit
End Cap
Screw, Hex Flange, M8 x 1.25
Housing O-Ring
Charge Pump Kit (Std. Charge)
Charge Pump Kit (Std. Charge) Thru
Shaft
STD Gerotor Assy (0.11 cu in./rev)
O-Ring
Cap Screw, Hex, 5/16 - 18 x 1.0
Bypass Valve Kit (No Bleed Orifice)
Pump Shaft Kit (1/2 in. Keyed w/Std.
Charge)
Pump Shaft Kit (1/2 in. Keyed, Thru
Shaft w Std. Charge
Pump Shaft Kit (9 tooth w/Std. Charge)
Ball Bearing, 17 x 40 x 12 mm
Lip Seal, 17 x 40 x 7 PTC
Spacer
Retaining Ring
Retaining Ring
Cylinder Block Kit
Block Spring
Swashplate
Ball Thrust Bearing
Trunnion Arm, Tapered Square
Trunnion
Arm, Double D
Slot Guide
Shock Valve Kit
2900 psi, (200 bar), No Orifice
2900 psi, (200 bar), 0.024 in. Orifice
2900 psi, (200 bar), 0.031 in. Orifice
2900 psi, (200 bar), 0.044 in. Orifice
2320 psi, (160 bar), No Orifice
2320 psi, (160 bar), 0.024 in. Orifice
2320 psi, (160 bar), 0.031 in. Orifice
2320 psi, (160 bar), 0.044 in. Orifice
1740 psi, (120 bar), No Orifice
1740 psi, (120 bar), 0.024 in. Orifice
1740 psi, (120 bar), 0.031 in. Orifice
1740 psi, (120 bar), 0.044 in. Orifice
PC Series
45
49
54
55
56
66
67
69
80
90
100
101
102
103
104
105
106
110
209
210
35
36
PC Series
REPAIR - PG and PE SERIES PUMP
Repair - PG and PE Series Pump.......................................................................................... 37-54
How to Use This Manual..............................................................................................................37
General Instructions.....................................................................................................................37
Tools and Torques........................................................................................................................38
Return to Neutral Linkage.............................................................................................................39
Standard Control Arm Linkage.....................................................................................................40
Fan Assembly...............................................................................................................................40
Input Shaft Seal............................................................................................................................41
Trunnion Arm Seal........................................................................................................................41
Check Valves................................................................................................................................42
Shock Valves................................................................................................................................42
Bypass..........................................................................................................................................43
Charge Pump-Standard or Thru Shaft..........................................................................................44
Auxiliary Pump..............................................................................................................................45
End Cap........................................................................................................................................46
Cylinder Block...............................................................................................................................47
Block Spring and Thrust Bearings................................................................................................48
Swashplate and Cradle Bearings.................................................................................................48
Input Shaft....................................................................................................................................49
Trunnion Arm................................................................................................................................50
Parts List................................................................................................................................. 52-53
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded
view showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 52 and
53 for part names and descriptions. A complete
exploded view and item list of the pump is provided
at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each pump.
These seals can be replaced without major disassembly of the unit. However, replacement of these
seals generally requires removal of the pump from
the machine. Upon removal, it is recommended that
all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly
clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with any
precision equipment, all parts must be kept free of
foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PG / PE Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
37
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
1/2-inch Socket
Torque Wrench
9/16-inch Socket
Scribe, Paint Pen, or Marker
5/8-inch Socket
Seal Hook with a Magnet
10-mm Socket
Flat Blade Screwdriver
Combination Wrenches
Pliers
1/2 inch
Internal Snap Ring
9/16 inch
5/8 inch
Allen Wrenches
7/8 inch
5mm
10 mm
3/16 inch
1/4 inch
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
Fan Nut, Hex Lock 5/16-24 UNF
4, End Cap Bolts
10, Cap Screw (Aux Pump and Shroud Bracket)
10, Cap Screw (Charge Pump Cover)
15, Bypass Valve
42A, 42B, Shock Valves/Check Plugs
44, System Charge Relief Kit (Aux Chg)
45, Aux Relief Valve Kit
56, Diagnostic Plug
66, Filter Cover Plug
67, Filter Cover
95, Screw, Socket Head Set
103, Screw 5/16 x .875
106, Bolt
107, Nut, Hex Lock 5/16-24UNF
200-250 lb-in (22.6-28.2 Nm)
370-470 lb-in (41.8-53.1 Nm)
200-250 lb-in (22.6-28.2 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
87-118 lb-in (9.8-13.3 Nm)
84-120 lb-in (9.4-13.5 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
84-120 lb-in (9.4-13.5 Nm)
55-85 lb-in (6.2-9.6 Nm)
200-275 lb-in (22.6-31.1 Nm)
100-185 lb-in (11.3-20.9 Nm)
200-240 lb-in (22.6-27.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
Table 2. PG / PE Pump Torque Values
38
PG / PE Series
PG and PE SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Refer to Figure 1.
Inspection
Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control
arm bracket.
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal
(49).
Disassembly
2. Inspect scissor arm (99) and all other linkage
parts for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
1. Loosen (but do not remove) the bolt (106)/
nut(107).
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
3. Remove the spring (102), bolt (106)/nut (107)
and washer (104).
4. Remove the scissor arm (99).
5. Remove the outer control arm bracket(94), bolt
(103), washer (104) and the inner return arm
bracket(98).
Assembly
1. Install the inner return arm bracket(98), washer
(104) and bolt (103).
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. Install the inner scissor control arm(94)
3. Tighten washer (104), and nut (103) to the
correct torque value. See page 38.
4. Install the scissor arm(99).
5. Install washer(104) and bolt (106)/nut(107) to
the correct torque value. See page 38.
5. Install the spring (102).
Prior to serial # 8001PXXXXX
104
107
After serial # 8001PXXXXX
Figure 1. PG / PE Pump Return to Neutral
PG / PE Series
39
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the bolt (106), washer (104) and
bushing (101).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket.
3. Remove bolt (103), washer (104) and the inner
control arm bracket.
2. Remove the nut (106) and fan assembly (90).
3. Remove the bolts (10) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal
(49).
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2. Inspect bushing (101) and all other linkage parts
for damage, corrosion or wear.
Assembly
1. Install the inner control arm bracket, washer
(104) and bolt (103).
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. Install the outer control arm bracket, bushing
(101), washer (104, and bolt (106). Tighten to
the correct torque value. See page 38.
Prior to serial # 8001PXXXX
Assembly
1. To install the mounting bracket (209), align and
insert the bolts (10) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (10) per table 2, page
38.
2. Install the fan and washer assembly onto the
shaft.
3. Install the nut (106) and tighten per table 2, page
38.
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
209
104
107
(2X) 10
90
After serial # 8001PXXXXX
Figure 2. PG / PE Pump Standard Control Arm
106
210
Figure 3. PG / PE Pump Fan Assembly
40
PG / PE Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION
ARM (CONTROL ARM) SEAL
Refer to Figure 4.
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (22) from housing.
1. Remove the retainer and lip seal (49) from the
housing (1). Care must be taken to prevent
damage to the housing trunnion bore, trunnion
arm (37) and sealing surface. Once removed
the retainer and lip seal is not reusable.
2. Remove lip seal (20). Care must be taken to
prevent damage to the housing bore, shaft
sealing surface, or bearing. Once removed, the
seal is not reusable.
Inspection
1. With seal removed inspect the spacer (21),
input shaft bearing (19) and housing (1) bore
for damage, corrosion or wear.
Assembly
1. Lubricate the new lip seal (20) inside diameter
with petroleum jelly.
2. Wrap the input shaft (18) with plastic wrap to
prevent damage to the inner surface of the lip
seal (20).
3. Slide seal (20) over shaft (18) so that lettering
on the seal faces out.
4. Press the lip seal (20) into the housing bore.
Insure the lip seal (20), shaft (18) or housing (1)
bore do not become damaged. Remove plastic
wrap.
5. Install the retaining ring (22) into the housing (1)
bore groove.
20
22
Inspection
1. With the lip seal (49) removed, inspect the area
for corrosion and wear. Inspect the trunnion bore
area sealing surface for damage or wear.
Assembly
1. Lubricate the new lip seal (49) with petroleum
jelly.
2. Wrap the trunnion arm (37) with plastic wrap to
prevent damage to the inner surface of the lip
seal (49).
3. Slide the lip seal (49) over the trunnion arm (37)
so that the lettering on the seal (49) faces out.
4. Press the lip seal (49) into the housing bore
(1). Insure the seal (49), trunnion arm (37), and
housing bore do not become damaged. Remove
the plastic wrap.
5. Install the retainer from (49) over the trunnion
arm (37) on top of the lip seal (49). Press into
the trunnion seal bore in the housing until the
retainer mates against the trunnion seal.
21
19
18
1
37
1
Figure 4. PG / PE Pump Input Shaft Seal
49
Figure 5. PG / PE Pump Trunnion Arm Seal
PG / PE Series
41
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CHECK VALVES
Refer to Figure 6.
Disassembly
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary
in “A” side to “B” side check configuration.
1. Remove the check valve (42) with an 1/4” allen
wrench.
2. Remove the valve spring and poppet from the
end cap (2).
Inspection
REMOVAL, INSPECTION AND/
OR REPLACEMENT OF SYSTEM
CHECK RELIEFS (SCR’S) OR
SHOCK VALVES
Refer to Figure 7.
Disassembly
Perform disassembly, inspection and assembly on
SCR/shock valve one side at a time. Some units
vary in “A” side to “B” side configuration.
1. Remove the SCR (42) with a 7/8” wrench or the
shock valve (42) with an 11/16” wrench.
1. Inspect the poppets and mating seats in the end
cap (2) for damage or foreign material.
2. Remove the check relief/shock valve spring and
the check relief/shock valve from the end cap
(2).
Assembly
Inspection
1. Lay the pump on its side, so the check plug port
is horizontal.
1. Inspect the check relief or shock valve (42) and
mating seat in the end cap (2) for damage or
foreign material.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten,
reference Table 2, page 38 for torque values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42A
(PORT “A”
SIDE)
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve as
one assembly into the check plug port. Tighten
to the correct torque value. See page 38.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
2
42B
(PORT “B”
SIDE)
Figure 6. PG / PE Pump Check Valves
42A
42B
2/25
Figure 7. PG / PE Pump Shock Valves
42
PG / PE Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (15) using a 5/8”
wrench.
2. Remove the bypass (15) from the end cap (2).
Inspection
1. Inspect the bypass O-rings and mating seats
in the end cap (2) for damage or foreign
materials.
2. If damaged or worn replace bypass (15)
Assembly
1. Lay the pump on its side, so the bypass port is
horizontal.
2. Insert the bypass (15) into the bypass port on
the end cap (2). Tighten to the proper torque
value. See page 38.
2
15
Figure 8. PG / PE Pump Bypass
PG / PE Series
43
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF STANDARD OR
THRU SHAFT CHARGE PUMP
NOTE: For the Thru Shaft charge pump
follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Refer to Figure 9.
Disassembly
1. Lubricate the new shaft seal with petroleum
jelly.
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Press the shaft seal into the charge cover. Be
careful not to damage the seal or charge cover
bore.
2. Using a 1/2 inch wrench, or 5 mm allen wrench,
loosen the charge pump cover bolts (10) from
the end cap (2). While holding the charge cover
in place, remove the charge cover bolts (10).
3. Position the pump with the input shaft down, and
the end cap (2) horizontal. Place the charge ball
(44) in the end cap (2) charge passage so the
ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
ball.
3. Remove the charge cover, O-ring and gerotor
items (6). Carefully check for and remove the
charge spring and charge ball (44).
4. Insert the inner gerotor over input shaft (18).
4. For the Thru Shaft charge pump, remove the
shaft seal.
5. Align the outer gerotor to fit over the inner
gerotor.
Inspection
6. Insert the O-ring into the groove in the charge
cover.
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap (2) for
damage or foreign material.
NOTE: If the end cap (2) is to be removed from the housing, do not assemble the charge pump (6) until the
end cap is installed on the housing.
2. Inspect the charge cover bore for damage,
corrosion or wear.
THRU SHAFT
7. Position the charge cover and O-ring with the
aligning mark on the end cap. Place the charge
cover and O-ring with aligning mark on the end
cap. Place the charge cover and O-ring as
one piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 38. (Torque
Values.)
44
6
6
18
2
(2X) 10
STANDARD
(2X) 10
Figure 9. PG / PE Pump Standard or Thru Shaft Charge Pump
44
PG / PE Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 10.
Disassembly
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
38.
Assembly
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump, charge pump (7)
and end cap (2) for alignment at assembly.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (10) from the end cap (2). While
holding the auxiliary pump in place, remove the
bolts (10).
2. Install the plug (56). Tighten to the correct torque
value. See page 38.
3. Install the poppet, spring and cap as one
assembly into the charge relief port. Tighten to
the correct torque value. See page 42.
3. Remove the auxiliary pump, gasket (75), O-ring
(59) and charge pump (7). While removing the
charge pump, be sure to retain the spring and
ball (44A) housed in the end cap (2).
4. Install the filter (54) and O-ring onto the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
4. Remove the plug (66) from the filter cover
(67).
5. Lay the PG pump (input shaft down), so the end
cap is horizontal. Install the O-ring (59) into the
charge pump (7).
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the auxiliary pump.
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44),
plug (56) and auxiliary relief valve assembly (45)
from the auxiliary pump.
Inspection
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
2. Inspect all O-rings, gasket and mounting
seats.
6. Install the gasket (75) onto the auxiliary pump.
7. Make sure that the ball and spring (44A) are
seated in the end cap (2), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
fully engages the alignment pins (69).
8. Align and insert the bolts (10) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (10) per
table 2, page 38.
44A
7
6
69
59
64
75
59
44
2
45
10
56
54
64
66
67
64
10
Figure 10. PG / PE Series Auxiliary Pump
PG / PE Series
45
NOTE: Grooving in the valve plate and or
end cap, made evident when the surface is
checked by dragging a fingernail across it,
would be cause for replacement of the valve
plate.
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP AND
VALVE PLATE
Refer to Figure 11a and 11b.
Disassembly
3. Inspect and replace alignment pins (3) if bent
or distorted.
1. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly.
4. Replace the housing gasket (5) with a new
gasket before reassembly.
2. Keeping the end cap (2) held in place, remove
the four end cap bolts (4).
Assembly
3. Slowly remove the end cap (2).
1. Install housing gasket (5) into housing gasket
seat of housing (1).
4. Remove the valve plate (31).
2. Install alignment pins (3) into housing (1).
NOTE: Not applicable in PE-series pumps.
6. Remove housing gasket (5).
3. Lubricate the valve plate prior to installation.
Install valve plate (31) so the stamped letters
“UP” on the valve plate are facing up toward
the end cap.
Inspection
1. Inspect the end cap body (2) for damage,
nicks or unusual wear patterns. Replace if
necessary.
4. Lubricate the end cap (2) face prior to
installation in PE-series pumps.
5. Remove housing alignment pins (3).
NOTE: Not applicable in PE-series pumps.
2. Inspect the running surface (side that contacts
the cylinder block) of the valve plate (31). The
running surface may show evidence of minor
abrasive rings, this is normal.
5. Install end cap (2). Before installing the four
end cap bolts (4), push down on the end cap
(2) verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten, reference
Table 2, page 38 torque values.
PG Series Pumps (With Valve Plate)
PE Series Pumps (No Valve Plate)
3
3
1
1
31
5
5
2
4
2
4
Figure 11a. PG Pump End Cap
46
Figure 11b. PE Pump End Cap
PG / PE Series
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Refer to Figure 12.
Assembly
1. Install piston seats into the end of the pistons.
2. Install springs into the pistons.
3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
Disassembly
1. Tilt the pump on its side, drain remaining oil. Lift
out the cylinder block assembly (25).
2. Remove the pistons, springs and piston seats.
Inspection
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This will be normal
wear. If grooved or smeared, replace with a new
cylinder block assembly.
2. Inspect the piston springs for distortion or
breaks. If necessary, replace with a new cylinder
block kit.
3. Inspect the piston seats. Residual oil may
cause these to remain stuck to the inside of the
pistons.
4. With the pump housing tilted on its side, install
the cylinder block assembly (25) with pistons
contacting the thrust bearing.
NOTE: To check that piston placement is
correct, push downward on the cylinder
block assembly (25). If this results in a
spring action the block assembly has
been installed correctly. If this cannot be
accomplished, remove and reassemble
the block assembly. Place a rubber band
around the cylinder block pistons to hold
them in position during installation. Then
after installation cut the rubber band and
remove it. Check cylinder block assembly for spring action.
25
Figure 12. PG / PE Pump Cylinder Block
PG / PE Series
47
REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING,
THRUST WASHER, AND THRUST
BEARING
Refer to Figure 13.
Refer to Figure 14.
Disassembly
Disassembly
1. Remove the block spring (29).
2. Remove the block thrust washer (30).
3. Remove the thrust bearing and race (34).
Inspection
1. Inspect and replace the block spring (29)
and thrust washer (30) if they are distorted or
broken.
2. Inspect the running surface of the bearing race
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor
abrasion. This will be normal wear.
REMOVAL, INSPECTION OF
SWASHPLATE, INSPECTION OF
CRADLE BEARINGS
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Assembly
1. Install thrust bearing and race assembly (34).
NOTE: The difference in race thicknesses: The thin race seats into the
swashplate (32). The thicker race will be
installed toward the piston noses.
2. Install thrust washer (30).
3. Install block spring (29).
1. Remove the swashplate (32).
Inspection
1. Inspect the running surface of the bearing pocket
for damage (32), nicks or unusual wear patterns.
The running surface may show evidence of
minor abrasion. This is normal wear. Inspect
the cradle bearing side of the swashplate (32)
for damage. Replace if necessary.
2. Inspect the cradle bearings attached to the inside
of the housing (1) for normal wear patterns,
placement, and insure they are staked securely
in place. If damaged, replace housing (1).
NOTE: The cradle bearings will have
discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (32) by holding trunnion
arm’s (37) slot guide (38) with the aide of a flat
tip screwdriver. Use the screwdriver to hold the
slot guide (38) in place while positioning the
swashplate (32) onto the cradle bearing in the
housing (1).
2. Rotate trunnion arm (37) to assure swashplate
pivoting action.
34
30
32
29
30
34
38
37
29
1
(Cradle bearings cannot be
removed from housing as depicted)
Figure 13. PG / PE Pump Block Spring and Thrust
Bearing
48
Figure 14. PG / PE Pump Swashplate and
Cradle Bearings
PG / PE Series
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
delay reassembly of input shaft assembly.
Refer to Figure 15.
Assembly
Disassembly
NOTE: Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. Remove the retaining ring (22).
2. Remove the lip seal (20).
3. Remove the spacer (21).
4. Remove the shaft (18) from the pump.
Inspection
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace
shaft assembly if necessary.
2. Inspect the bearing (19) for evidence of scoring,
corrosion, or damage. Replace shaft assembly
if necessary.
3. Inspect and replace the spacer (21) if it is bent
or broken.
4. Inspect and replace the retaining ring (22) if it
is bent or broken.
1. Install input shaft assembly (18, 19, 23) into the
housing (1) bore. Light tapping with a rubber
mallet may be necessary on the input shaft (18)
once the bearing is aligned with the housing (1)
bore. Rotate the input shaft (18) to insure free
movement.
2. Install spacer (21).
3. Install new lip seal (20).
4. Remove the plastic wrap.
5. Install retaining ring (22).
NOTE: Replace the input shaft seal (20)
after removal.
22
20
21
23
19
18
1
Figure 15. PG / PE Pump Input Shaft
PG / PE Series
49
REMOVAL AND INSPECTION OF
TRUNNION ARM
Refer to Figure 16.
1
Disassembly
1. Remove the slot guide (38).
2. Remove and discard the trunnion seal retainer
and seal (49).
3. Remove the trunnion arm (37).
Inspection
1. Inspect the trunnion arm (37) for wear or damage.
Replace the trunnion arm if necessary.
Assembly
38
37
49
Figure 16. PG / PE Pump Trunnion Arm
1. Install the trunnion arm (37) into the housing
(1) bore. Rotate the trunnion arm to verify free
movement.
NOTE: Upon removal, it is recommended
that all seals, O-rings, and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of seals
by covering the shaft with plastic wrap.
Remove the plastic wrap after the seal
is installed.
2. Install a new seal and seal retainer (49).
3. Install the slot guide (38).
4. To completely reassemble the pump, refer to
the assembly steps on pages 39-50. Begin
with the trunnion arm assembly steps listed on
page 54 and complete the assembly steps in
reverse order working towards the front of the
manual.
50
PG / PE Series
PG / PE Series
51
Figure 17. PG / PE Pump
52
PG / PE Series
BOXES INDICATE ITEMS INCLUDED IN KITS.
Kit Number
ITEM LIST - pg and PE SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No. Description
1 Housing Kit
2 End Cap Kit (W/Poppets, Standard Charge)
End Cap Kit (W/ SCR’S, Standard Charge)
End Cap Kit (W/ Poppets, Auxiliary Charge)
End Cap Kit (W/ SCR’S, Auxiliary Charge)
End Cap Kit (STD CHG) LH;SCR/HR: Poppet
End Cap Kit (STD CHG) LH:Poppet/RH:SCR
End Cap Kit (STD CHG) LH:SCR/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RH:Poppet
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RHPoppet, Thru
End Cap Kit (AUX CHG) W/Poppets, Thru
End Cap Kit (AUX CHG) W/SCR;s, Thru
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Thru
3 Straight Headless Pin
4 Hex Flange Bolt M8-1.25 X 60 mm LG
5 Housing O-Ring
6 Charge Pump Kit (STD)
Charge Pump Kit (STD CHG), Thru
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE Ports)
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE Ports)
7 STD Gerotor Assy (.11 cu. In/rev D-Drive)
Auxiliary Gerotor & Housing Assembly
8 O-Ring
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD Chg)
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg)
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg)
Supplied with item # 2 only
15 Bypass Valve Kit (Blank)
Bypass Valve Kit (0.031”)
Bypass Valve Kit (0.043”)
18 Pump Shaft Kit (Blind 15mm Keyway
W/Std Chg)
Pump Shaft Kit (Blind 15mm Keyway
W/Aux Chg)
Pump Shaft Kit (9 Tooth W/Std Chg)
Pump Shaft Kit (9 Tooth W/Aux Chg)
Pump Shaft Kit (15mm Keyed, Std Chg, Thru)
Pump Shaft Kit (9 Tooth Thru Chg)
Pump Shaft Kit (Tapered)
19 Ball Bearing 17 X 40 X 12
20 Lip Seal 17 X 40 X 7 PTC
21 Spacer
22 Retaining Ring
25 Cylinder Block Kit
29 Block Spring
30 Block Thrust Washer
31 Valve Plate
32 Swashplate
PG / PE Series
No. Description
34 Ball Thrust Bearing
35 Stud, Torque
37 Trunnion Arm
Trunnion, RTN
38 Slot Guide
42 Check Valve Kit (blank Orifice)
Check Valve Kit (0.024” Orifice)
Check Valve Kit (0.031” Orifice)
Check Valve Kit (0.044” Orifice)
System Check / Relief Kit
System Check Relief Kit (.031” Orifice)
Shock Valve Kit
44 Charge Relief Valve Kit (1/4” Plastic Ball
& 50654 Spring)
Charge Relief Valve Kit (9/16” SAE Plug
& 3101536 Spring)
45 Aux Relief Valve Kit (1/4” Steel Ball)
Aux Relief Valve Kit (Aux Poppet)
49 Trunnion Seal/Retainer Kit
54 Auxiliary Filter Kit
56 Straight Thread Plug
59 O-Ring
64 Connector
66 5/16” SAE Plug
67 Filter Cover
69 Straight Headless Pin
75 Shim - Charge Pump (.002 - Red)
85 R-Ring - 144
90 Hub / 6” Fan Kit
Hub / 7” CCW Fan Kit
Hub / 7” CW Fan Kit
Hug / 7” Fan Kit
94 Control Arm
95 Screw, Soc Head
98 Return Arm
99 Inner Scissor Arm
100 Outer Scissor Arm
101 Spacer RTN
102 Spring, Extension
103 Screw, 5/16 x .875 (patch)
104 Washer .34 x .88 x .06
105 Washer, Nylon
106 Bolt
107 Nut, Hex
110 Kit, RTN, STD
Kit, RTN, CW
Kit, RTN, CCW
111 Seal Kit
209 Shroud Bracket
210 Shroud
53
54
PG / PE Series
REPAIR - PJ SERIES PUMP
Repair - PJ Series Pump ...................................................................................................... 55-72
How to Use This Manual .............................................................................................................. 55
General Instructions .................................................................................................................... 55
Tools and Torques ....................................................................................................................... 56
Return to Neutral Linkage ............................................................................................................ 57
Standard Control Arm Linkage ..................................................................................................... 58
Fan Assembly .............................................................................................................................. 58
Input Shaft Seal ........................................................................................................................... 59
Trunnion Arm Seal ....................................................................................................................... 59
Check Valves ............................................................................................................................... 60
Shock Valves ............................................................................................................................... 60
Bypass ........................................................................................................................................ 61
Charge Pump-Standard or Thru Shaft......................................................................................... 62
Auxiliary Pump ............................................................................................................................. 63
End Cap ...................................................................................................................................... 64
Cylinder Block ............................................................................................................................. 65
Block Spring and Thrust Bearings ...............................................................................................66
Swashplate and Cradle Bearings ................................................................................................ 66
Input Shaft ................................................................................................................................... 67
Trunnion Arm ............................................................................................................................... 68
Parts List ............................................................................................................................... 70-71
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded view
showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 70 and 71
for part names and descriptions. A complete
exploded view and item list of the pump is provided
at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each pump.
These seals can be replaced without major
disassembly of the unit. However, replacement of
these seals generally requires removal of the pump
from the machine. Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly clean
all exposed surfaces prior to any type of
maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with
any precision equipment, all parts must be kept free
of foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PJ Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
55
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
7/16-inch Socket
Torque Wrench
1/2-inch Socket
Scribe, Paint Pen, or Marker
9/16-inch Socket
Seal Hook with a Magnet
5/8-inch Socket
Flat Blade Screwdriver
11/16-inch Socket
10-mm Socket
Pliers
Combination Wrenches
Internal Snap Ring
7/16 inch
Allen Wrenches
1/2 inch
5mm
9/16 inch
1/8 inch
5/8 inch
3/16 inch
11/16 inch
1/4 inch
7/8 inch
10 mm
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
4, End Cap/Adapter Plate Bolts
10, Cap Screw
15, Bypass Valve
42A, 42B, Shock Valves/Check Plugs
44, System Charge Relief Kit (Aux Chg)
45, Aux Relief Valve Kit
56, Diagnostic Plug
66, Filter Cover Plug
67, Filter Cover
103, Screw 5/16 x .875
106, Bolt
107, Nut, Hex Lock 5/16-24UNF
200-250 lb-in (22.6-28.2 Nm)
370-470 lb-in (41.8-53.1 Nm)
200-250 lb-in (22.6-28.2 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
110-130 lb-in (12.4-14.6 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
84-120 lb-in (9.4-13.5 Nm)
55-85 lb-in (6.2-9.6 Nm)
200-275 lb-in (22.6-31.1 Nm)
200-240 lb-in (22.6-27.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
Table 2. PJ Pump Torque Values
56
PJ Series
PJ SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Refer to Figure 1.
Inspection
Prior to disassembly, note the position of the scissor
arm brackets and the tab on the outer control arm
bracket.
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
Disassembly
2. Inspect scissor arm (99) and all other linkage
parts for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
Assembly
1. Loosen (but do not remove) the bolt (106)/nut
(107).
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
2. Install the inner scissor control arm(94)
1. Install the inner return arm bracket(98), washer
(104) and bolt (103).
3. Tighten washer (104), and nut (103) to the
correct torque value. See page 74.
3. Remove the spring (102), bolt (106)/nut (107)
and washer (104).
4. Install the scissor arm(99).
4. Remove the scissor arm (99).
5. Install washer(104) and bolt (106)/nut (107) to
the correct torque value. See page 74.
5. Remove the outer control arm bracket(94), bolt
(103), washer (104) and the inner return arm
bracket(98).
5. Install the spring (102).
Prior to serial # 8001PXXXXX
104
107
After serial # 8001PXXXXX
Figure 1. PJ Pump Return to Neutral
PJ Series
57
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the bolt (106)/nut (107), washer (104)
and bushing (101).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket.
3. Remove bolt (103), washer (104) and the inner
control arm bracket.
2. Remove the nut (106) and fan assembly (90).
3. Remove the bolts (10) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2.
Assembly
Inspect bushing (101) and all other linkage parts
for damage, corrosion or wear.
1. Install the inner control arm bracket, washer
(104) and bolt (103).
1. To install the mounting bracket (209), align and
insert the bolts (10) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (10) per table 2, page
56.
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. Install the fan and washer assembly onto the
shaft.
2. Install the outer control arm bracket, bushing
(101), washer (104, and bolt (106)/nut(107).
Tighten to the correct torque value. See page
56.
3. Install the nut (106) and tighten per table 2, page
56.
Assembly
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
Prior to serial # 8001PXXXXX
104
209
107
After serial # 8001PXXXXX
10
Figure 2. PJ Pump Standard Control Arm
106
90
210
Figure 3. PJ Pump Fan Assembly
58
PJ Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION ARM
SEAL
Refer to Figure 4.
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (22) from housing.
1. Remove the RTN assembly or control arm.
2. Remove lip seal (20). Care must be taken to
prevent damage to the housing bore, shaft
sealing surface, or bearing. Once removed, the
seal is not reusable.
2. Remove the retainer and lip seal (49) from the
housing. Care must be taken to prevent damage
to the housing trunnion bore, trunnion arm and
sealing surface. Once removed the retainer and
lip seal are not reusable.
Inspection
With seal removed inspect the spacer (21) and
housing (1) bore for damage, corrosion or wear.
Assembly
1. Lubricate the new lip seal (20) inside diameter
with petroleum jelly.
2. Wrap the input shaft with plastic wrap to prevent
damage to the inner surface of the lip seal (20).
Inspection
With the lip seal (49) removed, inspect the area for
corrosion and wear. Inspect the trunnion bore area
sealing surface for damage or wear.
Assembly
1. Lubricate the new lip seal (49) inside diameter
with petroleum jelly.
3. Slide spacer (21) and seal (20) over the input
shaft so that lettering on the seal faces out.
2. Wrap the trunnion arm with plastic wrap to
prevent damage to the inner surface of the lip
seal (49).
4. Press the lip seal (20) into the housing bore.
Insure the lip seal (20), input shaft or housing
(1) bore does not become damaged.
3. Slide the lip seal (49) over the trunnion arm so that
the lettering on the seal (49) faces out.
5. Install the retaining ring (22) into the housing bore
groove.
4. Press the lip seal (49) into the housing bore.
Insure the seal (49), trunnion arm, and housing
bore do not become damaged. Remove the
plastic wrap.
5. Install the retainer from (49) over the trunnion
arm on top of the lip seal. Press into the trunnion
seal bore in the housing until the retainer mates
against the trunnion seal.
22
20
6. Install the RTN assembly or control arm.
21
Figure 4. PJ Pump Input Shaft Seal
49
Figure 5. PJ Pump Trunnion Arm Seal
PJ Series
59
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CHECK VALVES
Refer to Figure 6.
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary in
“A” side to “B” side check configuration.
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF SYSTEM CHECK
RELIEFS (SCR’S) OR SHOCK
VALVES
Refer to Figure 7.
Disassembly
Disassembly
1. Remove the check valve (42) with an 1/4” allen
wrench.
Perform disassembly, inspection and assembly on
SCR/shock valve one side at a time. Some units
vary in “A” side to “B” side configuration.
2. Remove the valve spring and poppet from the
end cap.
Inspection
1. Inspect the poppets and mating seats in the end
cap for damage or foreign material.
1. Remove the SCR (42) with a 7/8” wrench or the
shock valve (42) with an 11/16” wrench.
2. Remove the check relief/shock valve spring and
the check relief/shock valve from the end cap.
Inspection
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten,
reference Table 2, page 56 for torque values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
1. Inspect the check relief or shock valve (42) and
mating seat in the end cap for damage or foreign
material.
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve as
one assembly into the check plug port. Tighten
to the correct torque value. See page 56.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42A
42A
42B
Figure 6. PJ Pump Check Valves
42B
Figure 7. PJ Pump Shock Valves
60
PJ Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (15) using a 5/8”
wrench.
2. Remove the bypass (15) from the end cap (2).
Inspection
1. Inspect the bypass O-rings and mating seats in
the end cap (2) for damage or foreign materials.
2. If damaged or worn replace bypass (15)
Assembly
1. Lay the pump on its side, so the bypass port is
horizontal.
2. Insert the bypass (15) into the bypass port on
the end cap (2). Tighten to the proper torque
value. See page 56.
15
Figure 8. PJ Pump Bypass
PJ Series
61
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF STANDARD OR
THRU SHAFT CHARGE PUMP
NOTE: For the Thru Shaft charge pump
follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum jelly.
Disassembly
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Using a 1/2 inch wrench, or 5 mm allen wrench,
loosen the charge pump cover bolts (10) from
the end cap (2). While holding the charge cover
in place, remove the charge cover bolts (10).
3. Remove the charge cover, O-ring and gerotor
items (6). Carefully check for and remove the
charge spring and charge ball (44).
4. For the Thru Shaft charge pump, remove the
shaft seal.
Inspection
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap (2) for
damage or foreign material.
NOTE: If the end cap (2) is to be removed from the housing, do not assemble the charge pump (6) until the
end cap is installed on the housing.
2. Inspect the charge cover bore for damage,
corrosion or wear.
2. Press the shaft seal into the charge cover. Be
careful not to damage the seal or charge cover
bore.
3. Position the pump with the input shaft down, and
the end cap (2) horizontal. Place the charge ball
(44) in the end cap (2) charge passage so the
ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
ball.
4. Insert the inner gerotor over input shaft (18).
5. Align the outer gerotor to fit over the inner gerotor.
6. Insert the O-ring (8) into the groove in the charge
cover.
7. Position the charge cover and O-ring with the
aligning mark on the end cap. Place the charge
cover and O-ring with aligning mark on the end
cap. Place the charge cover and O-ring as one
piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 56. (Torque
Values.)
44
6
18
THRU SHAFT
8
7
2
8
10
STANDARD
7
6
10
Figure 9. PJ Pump Standard or Thru Shaft Charge Pump
62
PJ Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 10.
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
56.
Disassembly
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump, charge pump (7)
and end cap (2) for alignment at assembly.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (10) from the end cap (2). While
holding the auxiliary pump in place, remove the
bolts (10).
3. Remove the auxiliary pump, gasket (75), O-ring
(8) and charge pump (7). While removing the
charge pump, be sure to retain the spring and
ball (44A) housed in the end cap (2).
Assembly
2. Install the poppet, spring and cap (44) as one
assembly into the charge relief port. Tighten to
the correct torque value. See page 56.
3. Install the filter (54) and O-ring onto the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
4. Lay the PJ Pump (input shaft down), so the end
cap is horizontal. Install the O-ring (8) into the
charge pump (7).
4. Remove the plug (66) from the filter cover (67).
5. Install the gasket (75) onto the auxiliary pump.
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the auxiliary pump.
6. Make sure that the ball and spring (44A) are
seated in the end cap (2), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
fully engages the alignment pins (69).
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44)
and auxiliary relief valve assembly (45) from the
auxiliary pump.
Inspection
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
7. Align and insert the bolts (10) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (10) per
table 2, page 56.
2. Inspect all O-rings, gasket and mounting seats.
44A
44
8
69
45
54
67
2
10
64
7
8
75
66
6
Figure 10. Auxiliary Pump
PJ Series
63
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP
3. Replace the housing gasket (5) with a new
gasket before assembly.
Assembly
Refer to Figure 11.
1. Install housing gasket (5) into gasket seat of
housing (1).
Disassembly
1. Remove charge pump. (See page 62).
2. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly.
2. Lubricate the cylinder block (25) to end cap (2)
mating surface with clean oil prior to installation.
5. Remove housing gasket (5).
3. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (92)
verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten to the correct
torque value. See Table 2, page 56 (Torque
Values).
Inspection
4. Install the charge pump. (See page 62.)
3. Hold the end cap (2) in place and remove the
four end cap bolts (4).
4. Slowly remove the end cap (2).
1.
Inspect the end cap (2) body for damage, nicks
or unusual wear patterns. Replace if necessary.
2. Inspect the running surface (side that contacts
the cylinder block) of the end cap (2). The
running surface may show evidence of minor
abrasive rings, this is normal.
Grooving in the end cap, or material transfer that
is evident when the surface is checked by
dragging a fingernail across it, would be cause
for replacement of the end cap (2).
1
4
25
4
2
5
Figure 11. PJ Pump End Cap
64
PJ Series
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Refer to Figure 12.
Disassembly
1. Remove charge pump. (See page 62).
2. Remove end cap. (See page 64).
3. Tilt the pump on its side and drain remaining oil.
Lift out the cylinder block assembly (25).
4. Remove the pistons, springs and piston seats.
Inspection
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This will be normal
wear. If grooved or smeared, replace with a new
cylinder block assembly.
2. Inspect the piston springs for distortion or breaks.
If necessary, replace with a new cylinder block
kit.
3. Inspect the piston seats. Residual oil may cause
these to remain stuck to the inside of the pistons.
2. Install piston seats into the end of the pistons.
3. Install springs into the pistons.
4. Install each piston, spring and seat assembly
into the cylinder block.
5. With the pump housing tilted on its side, install
the cylinder block assembly (25) with pistons
contacting the thrust bearing.
NOTE: To check if the cylinder block assembly is installed correctly, position the
pump housing vertically and support
housing at the mounting flange. Push
down on the cylinder block. The cylinder block must move up and down freely.
If it does not, remove the cylinder block
assembly. Place a rubber band around
the cylinder block pistons to hold them
in position during installation. Then after installation cut the rubber band and
remove it. Check cylinder block assembly for spring action.
6. Install the end cap. (See page 64)
7. Install the charge pump. (See page 62)
Assembly
1. Apply a thin layer of clean oil to the pistons and
springs.
25
Figure 12. PJ Pump Cylinder Block
PJ Series
65
REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING AND
THRUST BEARING
REMOVAL, INSPECTION AND
ASSEMBLY OF SWASHPLATE AND
CRADLE BEARINGS
Refer to Figure 13.
Refer to Figure 14.
Disassembly
Disassembly
1. Remove the block spring (29).
1. Remove the swashplate (32).
2. Remove the block thrust washer (30) and thrust
bearing (34).
Inspection
Inspection
1. Inspect and replace the block spring (29) if it is
distorted or broken.
2. Inspect the running surface of the bearing races
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor
abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Assembly
1. Install thrust bearing and race assembly (34).
2. Install the block thrust washer (30).
NOTE: The difference in race thicknesses: The thin race seats into the
swashplate (32). The thicker race will be
installed toward the piston noses.
3.
Install block spring (29).
1. Inspect the running surface of the bearing pocket
of swashplate (32) for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This is normal wear.
Inspect the cradle bearing side of the swashplate
(32) for damage. Replace if necessary.
2. Inspect the cradle bearings attached to the inside
of the housing (1) for normal wear patterns and
placement, and insure they are staked securely
in place. If the bearings are damaged, replace
housing (1).
NOTE: The cradle bearings will have discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (32) by holding trunnion arm’s
slot guide (38) with a flat tip screwdriver. Use
the screwdriver to hold the slot guide in place
while positioning the swashplate (32) onto the
cradle bearing in the housing (1).
2. Rotate trunnion arm (37) to verify that the
swashplate moves freely.
32
38
37
34
30
29
1
49
Figure 13. Pump Block Spring and Thrust Bearing
66
Figure 14. PJ Pump Swashplate and Cradle
Bearings
PJ Series
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
do not assemble input shaft until the trunnion arm is installed.
Refer to Figure 15.
Disassembly
1. Remove the retaining ring (22).
2. Remove the lip seal (20).
3. Remove the spacer (21).
4. Remove the shaft (18) and bearing (19)
assembly from the pump.
Inspection
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace
shaft assembly if necessary.
2. Inspect the bearing (19) for evidence of scoring,
corrosion, or damage. If the bearing must be
replaced, remove the retaining ring and use a
press or bearing puller to remove the bearing.
NOTE: During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. If removed, press bearing (19) onto shaft (18)
tight against the shoulder of the shaft. Install
retaining ring onto the shaft (18).
2. Install input shaft assembly (18) into the housing
(1) bore. Light tapping with a rubber mallet may
be necessary on the input shaft (18) once the
bearing is aligned with the housing (1) bore.
Verify that the shaft rotates smoothly.
3. Install spacer (21).
3. Inspect and replace the spacer (21) if it is bent
or broken.
4. Install new lip seal (20) with the flat side of the
seal toward the outside of the pump.
4. Inspect and replace the retaining ring (22) if it is
bent or broken.
5. Remove the plastic wrap.
6. Install retaining ring (22).
NOTE: Upon removal, all seals, O-rings
and gaskets should be replaced.
22
20
21
19
18
1
Figure 15. PJ Pump Input Shaft
PJ Series
67
REMOVAL, INSPECTION AND
INSTALLATION OF TRUNNION ARM
Refer to Figure 16.
Disassembly
1. Remove the slot guide (38).
2. Remove and discard the trunnion seal retainer
and seal (49).
3. Remove the trunnion arm (37).
Inspection
1. Inspect the trunnion arm (37) for wear or
damage. Replace the trunnion arm if necessary.
2.
Check for excessive play between trunnion arm
(37) and housing (1). Replace housing if
necessary.
Assembly
1. Install the trunnion arm (37) into the housing (1)
bore. Rotate the trunnion arm to verify free
movement.
2. Install a new seal and seal retainer (49).
3. Install slot guide (38).
4. To completely assembly the pump, refer to the
assembly steps on pages 57-68. Begin with the
trunnion arm assembly steps listed on page 68
and complete the assembly steps in reverse
order working toward the front of the manual.
32
38
37
1
49
Figure 16. PJ Pump Trunnion Arm
68
PJ Series
PJ Series
69
Figure 17. PJ Pump
70
PJ Series
BOXES INDICATE ITEMS INCLUDED IN KITS.
Kit Number
ITEM LIST - PJ SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No.
Description
1 Housing Kit
2 End Cap Kit (W/Poppets, Standard Charge)
End Cap Kit (W/ SCR’S, Standard Charge)
End Cap Kit (W/ Poppets, Auxiliary Charge)
End Cap Kit (W/ SCR’S, Auxiliary Charge)
End Cap Kit (STD CHG) LH;SCR/HR: Poppet
End Cap Kit (STD CHG) LH:Poppet/RH:SCR
End Cap Kit (STD CHG) LH:SCR/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RH:Poppet
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RHPoppet, Thru
End Cap Kit (AUX CHG) W/Poppets, Thru
End Cap Kit (AUX CHG) W/SCR;s, Thru
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Thru
3 Straight Headless Pin
4 Hex Flange Bolt M8-1.25 X 60 mm LG
5 Housing O-Ring
6 Charge Pump Kit (STD)
Charge Pump Kit (STD CHG), Thru
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE
Ports)
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE
Ports)
7 STD Gerotor Assy (.11 cu. In/rev D-Drive)
Auxiliary Gerotor & Housing Assembly
8 O-Ring
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD
CHg)
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg)
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg)
Supplied with item # 2 only
15 Bypass Valve Kit (Blank)
Bypass Valve Kit (0.031”)
Bypass Valve Kit (0.043”)
18 Pump Shaft Kit (Blind 15mm Keyway
W/Std Chg)
Pump Shaft Kit (Blind 15mm Keyway
W/Aux Chg)
Pump Shaft Kit (9 Tooth W/Std Chg)
Pump Shaft Kit (9 Tooth W/Aux Chg)
Pump Shaft Kit (15mm Keyed, Std Chg, Thru)
Pump Shaft Kit (9 Tooth Thru Chg)
Pump Shaft Kit (Tapered)
19 Ball Bearing 17 X 40 X 12
20 Lip Seal 17 X 40 X 7 PTC
21 Spacer
22 Retaining Ring
25 Cylinder Block Kit
29 Block Spring
30 Block Thrust Washer
32 Swashplate
PJ Series
No.
34
35
37
38
42
44
45
49
54
55
56
59
64
66
67
69
75
80
85
90
98
99
100
101
102
103
104
105
106
107
110
209
210
Description
Ball Thrust Bearing
Stud, Torque
Trunnion Arm
Trunnion, RTN
Slot Guide
Check Valve Kit (blank Orifice)
Check Valve Kit (0.024” Orifice)
Check Valve Kit (0.031” Orifice)
Check Valve Kit (0.044” Orifice)
System Check / Relief Kit
System Check Relief Kit (.031” Orifice)
Shock Valve Kit
Charge Relief Valve Kit (1/4” Plastic Ball
& 50654 Spring)
Charge Relief Valve Kit (9/16” SAE Plug
& 3101536 Spring)
Aux Relief Valve Kit (1/4” Steel Ball)
Aux Relief Valve Kit (Aux Poppet)
Trunnion Seal/Retainer Kit
Auxiliary Filter Kit
Plate, Adapter (Gear A)
Straight Thread Plug
O-Ring
Connector
5/16” SAE Plug
Filter Cover
Straight Headless Pin
Shim - Charge Pump (.002 - Red)
Pin, Straight Headless
R-Ring - 144
Hub / 6” Fan Kit
Hub / 7” CCW Fan Kit
Hub / 7” CW Fan Kit
Hug / 7” Fan Kit
Return Arm
Inner Scissor Arm
Seal Kit
Spacer RTN
Spring, Extension
Screw, 5/16 x .875 (patch)
Washer .34 x .88 x .06
Washer, Nylon
Bolt
Nut, Hex Lock 5/16 - 24 UNF
Kit, RTN, STD
Kit, RTN, CW
Kit, RTN, CCW
Shroud Bracket
Shroud
71
72
PJ Series
REPAIR - PK SERIES PUMP
Repair - PK Series Pump ...................................................................................................... 73-90
How to Use This Manual .............................................................................................................. 73
General Instructions .................................................................................................................... 73
Tools and Torques ....................................................................................................................... 74
Return to Neutral Linkage ............................................................................................................ 75
Standard Control Arm Linkage ..................................................................................................... 76
Fan Assembly .............................................................................................................................. 76
Input Shaft Seal ........................................................................................................................... 77
Trunnion Arm Seal ....................................................................................................................... 77
Check Valves ............................................................................................................................... 78
Shock Valves ............................................................................................................................... 78
Bypass ........................................................................................................................................ 79
Charge Pump-Standard or Thru Shaft......................................................................................... 80
Auxiliary Pump ............................................................................................................................. 81
End Cap ...................................................................................................................................... 82
Cylinder Block ............................................................................................................................. 83
Block Spring and Thrust Bearings ...............................................................................................84
Swashplate and Cradle Bearings ................................................................................................ 84
Input Shaft ................................................................................................................................... 85
Trunnion Arm ............................................................................................................................... 86
Parts List ............................................................................................................................... 88-89
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded view
showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 88 and 89
for part names and descriptions. A complete
exploded view and item list of the pump is provided
at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each pump.
These seals can be replaced without major
disassembly of the unit. However, replacement of
these seals generally requires removal of the pump
from the machine. Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly clean
all exposed surfaces prior to any type of
maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with
any precision equipment, all parts must be kept free
of foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PK Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
73
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
7/16-inch Socket
Torque Wrench
1/2-inch Socket
Scribe, Paint Pen, or Marker
9/16-inch Socket
Seal Hook with a Magnet
5/8-inch Socket
Flat Blade Screwdriver
11/16-inch Socket
10-mm Socket
Pliers
Combination Wrenches
Internal Snap Ring
7/16 inch
Allen Wrenches
1/2 inch
5mm
9/16 inch
1/8 inch
5/8 inch
3/16 inch
11/16 inch
1/4 inch
7/8 inch
10 mm
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
4, End Cap/Adapter Plate Bolts
10, Cap Screw
15, Bypass Valve
42A, 42B, Shock Valves/Check Plugs
44, System Charge Relief Kit (Aux Chg)
45, Aux Relief Valve Kit
56, Diagnostic Plug
66, Filter Cover Plug
67, Filter Cover
103, Screw 5/16 x .875
106, Bolt
200-250 lb-in (22.6-28.2 Nm)
370-470 lb-in (41.8-53.1 Nm)
200-250 lb-in (22.6-28.2 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-220 lb-in (20.3-24.9 Nm)
110-130 lb-in (12.4-14.6 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
84-120 lb-in (9.4-13.5 Nm)
55-85 lb-in (6.2-9.6 Nm)
200-275 lb-in (22.6-31.1 Nm)
200-240 lb-in (22.6-27.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
Table 2. PK Pump Torque Values
74
PK Series
PK SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Refer to Figure 1.
Inspection
Prior to disassembly, note the position of the scissor
arm brackets and the tab on the outer control arm
bracket.
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
Disassembly
2. Inspect scissor arm (99) and all other linkage
parts for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
Assembly
1. Loosen (but do not remove) the bolt (106).
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
3. Remove the spring (102), bolt(106) washer
(104).
4. Remove the scissor arm (99).
5. Remove the outer control arm bracket(94), bolt
(103), washer (104) and the inner return arm
bracket(98).
1. Install the inner return arm bracket(98), washer
(104) and bolt (103).
2. Install the inner scissor control arm(94)
3. Tighten washer (104), and nut (103) to the
correct torque value. See page 74.
4. Install the scissor arm(99).
5. Install washer(104) and bolt (106) to the correct
torque value. See page 74.
5. Install the spring (102).
Figure 1. PK Pump Return to Neutral
PK Series
75
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the bolt (106), washer (104) and
bushing (101).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket.
3. Remove bolt (103), washer (104) and the inner
control arm bracket.
2. Remove the nut (106) and fan assembly (90).
3. Remove the bolts (10) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (37) and trunnion arm seal (49).
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2.
Assembly
Inspect bushing (101) and all other linkage parts
for damage, corrosion or wear.
1. Install the inner control arm bracket, washer
(104) and bolt (103).
1. To install the mounting bracket (209), align and
insert the bolts (10) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (10) per table 2, page
74.
NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. Install the fan and washer assembly onto the
shaft.
2. Install the outer control arm bracket, bushing
(101), washer (104, and bolt (106). Tighten to
the correct torque value. See page 74.
3. Install the nut (106) and tighten per table 2, page
74.
Assembly
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
209
10
Figure 2. PK Pump Standard Control Arm
106
90
210
Figure 3. PK Pump Fan Assembly
76
PK Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION ARM
SEAL
Refer to Figure 4.
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (22) from housing.
1. Remove the RTN assembly or control arm.
2. Remove lip seal (20). Care must be taken to
prevent damage to the housing bore, shaft
sealing surface, or bearing. Once removed, the
seal is not reusable.
2. Remove the retainer and lip seal (49) from the
housing. Care must be taken to prevent damage
to the housing trunnion bore, trunnion arm and
sealing surface. Once removed the retainer and
lip seal are not reusable.
Inspection
With seal removed inspect the spacer (21) and
housing (1) bore for damage, corrosion or wear.
Assembly
1. Lubricate the new lip seal (20) inside diameter
with petroleum jelly.
2. Wrap the input shaft with plastic wrap to prevent
damage to the inner surface of the lip seal (20).
Inspection
With the lip seal (49) removed, inspect the area for
corrosion and wear. Inspect the trunnion bore area
sealing surface for damage or wear.
Assembly
1. Lubricate the new lip seal (49) inside diameter
with petroleum jelly.
3. Slide spacer (21) and seal (20) over the input
shaft so that lettering on the seal faces out.
2. Wrap the trunnion arm with plastic wrap to
prevent damage to the inner surface of the lip
seal (49).
4. Press the lip seal (20) into the housing bore.
Insure the lip seal (20), input shaft or housing
(1) bore does not become damaged.
3. Slide the lip seal (49) over the trunnion arm so that
the lettering on the seal (49) faces out.
5. Install the retaining ring (22) into the housing bore
groove.
4. Press the lip seal (49) into the housing bore.
Insure the seal (49), trunnion arm, and housing
bore do not become damaged. Remove the
plastic wrap.
5. Install the retainer from (49) over the trunnion
arm on top of the lip seal. Press into the trunnion
seal bore in the housing until the retainer mates
against the trunnion seal.
22
20
6. Install the RTN assembly or control arm.
21
Figure 4. PK Pump Input Shaft Seal
49
Figure 5. PK Pump Trunnion Arm Seal
PK Series
77
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CHECK VALVES
Refer to Figure 6.
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary in
“A” side to “B” side check configuration.
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF SYSTEM CHECK
RELIEFS (SCR’S) OR SHOCK
VALVES
Refer to Figure 7.
Disassembly
Disassembly
1. Remove the check valve (42) with an 1/4” allen
wrench.
Perform disassembly, inspection and assembly on
SCR/shock valve one side at a time. Some units
vary in “A” side to “B” side configuration.
2. Remove the valve spring and poppet from the
end cap.
Inspection
1. Inspect the poppets and mating seats in the end
cap for damage or foreign material.
1. Remove the SCR (42) with a 7/8” wrench or the
shock valve (42) with an 11/16” wrench.
2. Remove the check relief/shock valve spring and
the check relief/shock valve from the end cap.
Inspection
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten,
reference Table 2, page 74 for torque values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
1. Inspect the check relief or shock valve (42) and
mating seat in the end cap for damage or foreign
material.
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve as
one assembly into the check plug port. Tighten
to the correct torque value. See page 74.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42A
42A
42B
Figure 6. PK Pump Check Valves
42B
Figure 7. PK Pump Shock Valves
78
PK Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (15) using a 5/8”
wrench.
2. Remove the bypass (15) from the end cap (2).
Inspection
1. Inspect the bypass O-rings and mating seats in
the end cap (2) for damage or foreign materials.
2. If damaged or worn replace bypass (15)
Assembly
1. Lay the pump on its side, so the bypass port is
horizontal.
2. Insert the bypass (15) into the bypass port on
the end cap (2). Tighten to the proper torque
value. See page 74.
15
Figure 8. PK Pump Bypass
PK Series
79
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF STANDARD OR
THRU SHAFT CHARGE PUMP
NOTE: For the Thru Shaft charge pump
follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum jelly.
Disassembly
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Using a 1/2 inch wrench, or 5 mm allen wrench,
loosen the charge pump cover bolts (10) from
the end cap (2). While holding the charge cover
in place, remove the charge cover bolts (10).
3. Remove the charge cover, O-ring and gerotor
items (6). Carefully check for and remove the
charge spring and charge ball (44).
4. For the Thru Shaft charge pump, remove the
shaft seal.
Inspection
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap (2) for
damage or foreign material.
NOTE: If the end cap (2) is to be removed from the housing, do not assemble the charge pump (6) until the
end cap is installed on the housing.
2. Inspect the charge cover bore for damage,
corrosion or wear.
2. Press the shaft seal into the charge cover. Be
careful not to damage the seal or charge cover
bore.
3. Position the pump with the input shaft down, and
the end cap (2) horizontal. Place the charge ball
(44) in the end cap (2) charge passage so the
ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
ball.
4. Insert the inner gerotor over input shaft (18).
5. Align the outer gerotor to fit over the inner gerotor.
6. Insert the O-ring (8) into the groove in the charge
cover.
7. Position the charge cover and O-ring with the
aligning mark on the end cap. Place the charge
cover and O-ring with aligning mark on the end
cap. Place the charge cover and O-ring as one
piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 74. (Torque
Values.)
44
6
18
THRU SHAFT
8
7
2
8
10
STANDARD
7
6
10
Figure 9. PK Pump Standard or Thru Shaft Charge Pump
80
PK Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 10.
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
74.
Disassembly
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump, charge pump (7)
and end cap (2) for alignment at assembly.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (10) from the end cap (2). While
holding the auxiliary pump in place, remove the
bolts (10).
3. Remove the auxiliary pump, gasket (75), O-ring
(8) and charge pump (7). While removing the
charge pump, be sure to retain the spring and
ball (44A) housed in the end cap (2).
Assembly
2. Install the poppet, spring and cap (44) as one
assembly into the charge relief port. Tighten to
the correct torque value. See page 74.
3. Install the filter (54) and O-ring onto the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
4. Lay the PJ Pump (input shaft down), so the end
cap is horizontal. Install the O-ring (8) into the
charge pump (7).
4. Remove the plug (66) from the filter cover (67).
5. Install the gasket (75) onto the auxiliary pump.
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the auxiliary pump.
6. Make sure that the ball and spring (44A) are
seated in the end cap (2), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
fully engages the alignment pins (69).
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44)
and auxiliary relief valve assembly (45) from the
auxiliary pump.
Inspection
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
7. Align and insert the bolts (10) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (10) per
table 2, page 74.
2. Inspect all O-rings, gasket and mounting seats.
44A
44
8
69
45
54
67
2
10
64
7
8
75
66
6
Figure 10. Auxiliary Pump
PK Series
81
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP
3. Replace the housing gasket (5) with a new
gasket before assembly.
Assembly
Refer to Figure 11.
1. Install housing gasket (5) into gasket seat of
housing (1).
Disassembly
1. Remove charge pump. (See page 62).
2. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly.
2. Lubricate the cylinder block (25) to end cap (2)
mating surface with clean oil prior to installation.
5. Remove housing gasket (5).
3. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (92)
verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten to the correct
torque value. See Table 2, page 74 (Torque
Values).
Inspection
4. Install the charge pump. (See page 80.)
3. Hold the end cap (2) in place and remove the
four end cap bolts (4).
4. Slowly remove the end cap (2).
1.
Inspect the end cap (2) body for damage, nicks
or unusual wear patterns. Replace if necessary.
2. Inspect the running surface (side that contacts
the cylinder block) of the end cap (2). The
running surface may show evidence of minor
abrasive rings, this is normal.
Grooving in the end cap, or material transfer that
is evident when the surface is checked by
dragging a fingernail across it, would be cause
for replacement of the end cap (2).
1
4
25
4
2
5
Figure 11. PK Pump End Cap
82
PK Series
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Refer to Figure 12.
Disassembly
1. Remove charge pump. (See page 80.
2. Remove end cap. (See page 82).
3. Tilt the pump on its side and drain remaining oil.
Lift out the cylinder block assembly (25).
4. Remove the pistons, springs and piston seats.
Inspection
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This will be normal
wear. If grooved or smeared, replace with a new
cylinder block assembly.
2. Inspect the piston springs for distortion or breaks.
If necessary, replace with a new cylinder block
kit.
3. Inspect the piston seats. Residual oil may cause
these to remain stuck to the inside of the pistons.
2. Install piston seats into the end of the pistons.
3. Install springs into the pistons.
4. Install each piston, spring and seat assembly
into the cylinder block.
5. With the pump housing tilted on its side, install
the cylinder block assembly (25) with pistons
contacting the thrust bearing.
NOTE: To check if the cylinder block assembly is installed correctly, position the
pump housing vertically and support
housing at the mounting flange. Push
down on the cylinder block. The cylinder block must move up and down freely.
If it does not, remove the cylinder block
assembly. Place a rubber band around
the cylinder block pistons to hold them
in position during installation. Then after installation cut the rubber band and
remove it. Check cylinder block assembly for spring action.
6. Install the end cap. (See page 82)
7. Install the charge pump. (See page 80)
Assembly
1. Apply a thin layer of clean oil to the pistons and
springs.
25
Figure 12. PK Pump Cylinder Block
PK Series
83
REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING AND
THRUST BEARING
REMOVAL, INSPECTION AND
ASSEMBLY OF SWASHPLATE AND
CRADLE BEARINGS
Refer to Figure 13.
Refer to Figure 14.
Disassembly
Disassembly
1. Remove the block spring (29).
1. Remove the swashplate (32).
2. Remove the block thrust washer (30) and thrust
bearing (34).
Inspection
Inspection
1. Inspect and replace the block spring (29) if it is
distorted or broken.
2. Inspect the running surface of the bearing races
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor
abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Assembly
1. Install thrust bearing and race assembly (34).
2. Install the block thrust washer (30).
NOTE: The difference in race thicknesses: The thin race seats into the
swashplate (32). The thicker race will be
installed toward the piston noses.
3.
Install block spring (29).
1. Inspect the running surface of the bearing pocket
of swashplate (32) for damage, nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion. This is normal wear.
Inspect the cradle bearing side of the swashplate
(32) for damage. Replace if necessary.
2. Inspect the cradle bearings attached to the inside
of the housing (1) for normal wear patterns and
placement, and insure they are staked securely
in place. If the bearings are damaged, replace
housing (1).
NOTE: The cradle bearings will have discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (32) by holding trunnion arm’s
slot guide (38) with a flat tip screwdriver. Use
the screwdriver to hold the slot guide in place
while positioning the swashplate (32) onto the
cradle bearing in the housing (1).
2. Rotate trunnion arm (37) to verify that the
swashplate moves freely.
32
38
37
34
30
29
1
49
Figure 13. Pump Block Spring and Thrust Bearing
84
Figure 14. PK Pump Swashplate and Cradle
Bearings
PK Series
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
do not assemble input shaft until the trunnion arm is installed.
Refer to Figure 15.
Disassembly
1. Remove the retaining ring (22).
2. Remove the lip seal (20).
3. Remove the spacer (21).
4. Remove the shaft (18) and bearing (19)
assembly from the pump.
Inspection
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace
shaft assembly if necessary.
2. Inspect the bearing (19) for evidence of scoring,
corrosion, or damage. If the bearing must be
replaced, remove the retaining ring and use a
press or bearing puller to remove the bearing.
NOTE: During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. If removed, press bearing (19) onto shaft (18)
tight against the shoulder of the shaft. Install
retaining ring onto the shaft (18).
2. Install input shaft assembly (18) into the housing
(1) bore. Light tapping with a rubber mallet may
be necessary on the input shaft (18) once the
bearing is aligned with the housing (1) bore.
Verify that the shaft rotates smoothly.
3. Install spacer (21).
3. Inspect and replace the spacer (21) if it is bent
or broken.
4. Install new lip seal (20) with the flat side of the
seal toward the outside of the pump.
4. Inspect and replace the retaining ring (22) if it is
bent or broken.
5. Remove the plastic wrap.
6. Install retaining ring (22).
NOTE: Upon removal, all seals, O-rings
and gaskets should be replaced.
22
20
21
19
18
1
Figure 15. PK Pump Input Shaft
PK Series
85
REMOVAL, INSPECTION AND
INSTALLATION OF TRUNNION ARM
Refer to Figure 16.
Disassembly
1. Remove the slot guide (38).
2. Remove and discard the trunnion seal retainer
and seal (49).
3. Remove the trunnion arm (37).
Inspection
1. Inspect the trunnion arm (37) for wear or
damage. Replace the trunnion arm if necessary.
2.
Check for excessive play between trunnion arm
(37) and housing (1). Replace housing if
necessary.
Assembly
1. Install the trunnion arm (37) into the housing (1)
bore. Rotate the trunnion arm to verify free
movement.
2. Install a new seal and seal retainer (49).
3. Install slot guide (38).
4. To completely assembly the pump, refer to the
assembly steps on pages 75-86. Begin with the
trunnion arm assembly steps listed on page 86
and complete the assembly steps in reverse
order working toward the front of the manual.
32
38
37
1
49
Figure 16. PK Pump Trunnion Arm
86
PK Series
PK Series
87
Figure 17. PK Pump
88
PK Series
BOXES INDICATE ITEMS INCLUDED IN KITS.
Kit Number
ITEM LIST - PK SERIES
Part numbers are not provided in this manual. See website for part numbers.
No.
Description
1 Housing Kit
2 End Cap Kit (W/Poppets, Standard Charge)
End Cap Kit (W/ SCR’S, Standard Charge)
End Cap Kit (W/ Poppets, Auxiliary Charge)
End Cap Kit (W/ SCR’S, Auxiliary Charge)
End Cap Kit (STD CHG) LH;SCR/HR: Poppet
End Cap Kit (STD CHG) LH:Poppet/RH:SCR
End Cap Kit (STD CHG) LH:SCR/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RH:Poppet
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR
End Cap Kit (AUX CHG) LH:SCR/RHPoppet, Thru
End Cap Kit (AUX CHG) W/Poppets, Thru
End Cap Kit (AUX CHG) W/SCR;s, Thru
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Thru
3 Straight Headless Pin
4 Hex Flange Bolt M8-1.25 X 60 mm LG
5 Housing O-Ring
6 Charge Pump Kit (STD)
Charge Pump Kit (STD CHG), Thru
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE
Ports)
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE
Ports)
7 STD Gerotor Assy (.11 cu. In/rev D-Drive)
Auxiliary Gerotor & Housing Assembly
8 O-Ring
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD
CHg)
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg)
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg)
Supplied with item # 2 only
15 Bypass Valve Kit (Blank)
Bypass Valve Kit (0.031”)
Bypass Valve Kit (0.043”)
18 Pump Shaft Kit (Blind 15mm Keyway
W/Std Chg)
Pump Shaft Kit (Blind 15mm Keyway
W/Aux Chg)
Pump Shaft Kit (9 Tooth W/Std Chg)
Pump Shaft Kit (9 Tooth W/Aux Chg)
Pump Shaft Kit (15mm Keyed, Std Chg, Thru)
Pump Shaft Kit (9 Tooth Thru Chg)
Pump Shaft Kit (Tapered)
19 Ball Bearing 17 X 40 X 12
20 Lip Seal 17 X 40 X 7 PTC
21 Spacer
22 Retaining Ring
25 Cylinder Block Kit
29 Block Spring
30 Block Thrust Washer
32 Swashplate
PK Series
No.
34
35
37
38
42
44
45
49
54
55
56
59
64
66
67
69
75
80
85
90
98
99
100
101
102
103
104
105
106
110
209
210
Description
Ball Thrust Bearing
Stud, Torque
Trunnion Arm
Trunnion, RTN
Slot Guide
Check Valve Kit (blank Orifice)
Check Valve Kit (0.024” Orifice)
Check Valve Kit (0.031” Orifice)
Check Valve Kit (0.044” Orifice)
System Check / Relief Kit
System Check Relief Kit (.031” Orifice)
Shock Valve Kit
Charge Relief Valve Kit (1/4” Plastic Ball
& 50654 Spring)
Charge Relief Valve Kit (9/16” SAE Plug
& 3101536 Spring)
Aux Relief Valve Kit (1/4” Steel Ball)
Aux Relief Valve Kit (Aux Poppet)
Trunnion Seal/Retainer Kit
Auxiliary Filter Kit
Plate, Adapter (Gear A)
Straight Thread Plug
O-Ring
Connector
5/16” SAE Plug
Filter Cover
Straight Headless Pin
Shim - Charge Pump (.002 - Red)
Pin, Straight Headless
R-Ring - 144
Hub / 6” Fan Kit
Hub / 7” CCW Fan Kit
Hub / 7” CW Fan Kit
Hug / 7” Fan Kit
Return Arm
Scissor Arm
Seal Kit
Spacer RTN
Spring, Extension
Screw, 5/16 x .875 (patch)
Washer .34 x .88 x .06
Washer, Nylon
Bolt
Kit, RTN, STD
Kit, RTN, CW
Kit, RTN, CCW
Shroud Bracket
Shroud
89
90
PK Series
REPAIR - PR SERIES PUMP
Repair - PR Series Pump..................................................................................................... 91-108
How to Use This Manual..............................................................................................................91
General Instructions.....................................................................................................................91
Tools and Torques........................................................................................................................92
Return to Neutral Linkage.............................................................................................................93
Standard Control Arm Linkage.....................................................................................................94
Fan Assembly...............................................................................................................................94
Input Shaft Seal............................................................................................................................95
Trunnion Arm Seal........................................................................................................................95
Check Valves................................................................................................................................96
Shock Valves................................................................................................................................96
Bypass..........................................................................................................................................97
Charge Pump-Standard or Thru Shaft..........................................................................................98
Auxiliary Pump..............................................................................................................................99
End Cap......................................................................................................................................100
Cylinder Block.............................................................................................................................101
Block Spring and Thrust Bearings..............................................................................................102
Swashplate and Cradle Bearings...............................................................................................102
Input Shaft..................................................................................................................................103
Trunnion Arm..............................................................................................................................104
Parts List............................................................................................................................. 106-107
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded
view showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 106 and
107 for part names and descriptions. A complete
exploded view and item list of the pump is provided
at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each pump.
These seals can be replaced without major disassembly of the unit. However, replacement of these
seals generally requires removal of the pump from
the machine. Upon removal, it is recommended that
all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly
clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with any
precision equipment, all parts must be kept free of
foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PR Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
91
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
1/2-inch Socket
Torque Wrench
9/16-inch Socket
Scribe, Paint Pen, or Marker
5/8-inch Socket
Seal Hook with a Magnet
10-mm Socket
Flat Blade Screwdriver
Combination Wrenches
Pliers
1/2 inch
Internal Snap Ring
9/16 inch
5/8 inch
Allen Wrenches
7/8 inch
5mm
10 mm
3/16 inch
1/4 inch
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
Fan Nut, Hex Lock 5/16-24 UNF
42A, 42B, Shock Valves/Check Plugs
45, Aux Relief Valve Kit
49, Aux Bypass/Check Kit
50, Bypass Valve
56, Screw
58, Hex Screw
67, Filter Cover
102, Cap Screw, Socket Head M8 x 1.25 x 25
107, Screw, 5/16-24 x .75
151, Diagnostic Plug
156, Filter Cover Plug
200-250 lb-in (22.6-28.2 Nm)
370-470 lb-in (41.8-53.1 Nm)
200-250 lb-in (22.6-28.2 Nm)
160-220 lb-in (18.1-24.9 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
95-120 lb-in (10.7-13.5 Nm)
180-220 lb-in (20.3-24.9 Nm)
255-300 lb-in (28.8-33.9 Nm)
200-275 lb-in (22.6-31.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
200-240 lb-in (22.6-27.1 Nm)
85-120 lb-in (9.6-13.5 Nm)
55-85 lb-in (6.2-9.6 Nm)
Table 2. PR Pump Torque Values
92
PR Series
PR SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control
arm bracket.
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (13) and trunnion arm seal
(12).
See Figure 1.
Disassembly
2. Inspect bushing (106) and all other linkage parts
for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
Assembly
1. Install the inner return arm bracket (105), washer
(99) and bolt (107).
1. Loosen (but do not remove) the bolt (102).
NOTE: Do not over tighten the bolt (107). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
2. Install the outer control arm bracket (101),
washer (109) and bushing (106).
3. Remove the spring (108), bolt (102), washer
(99) and outer scissor arm bracket (103).
3. Install the inner scissor control arm bracket
(104), washer (109), and outer scissor control
arm bracket (103).
4. Remove bushing (106), washers (109), and the
inner scissor arm bracket (104).
4. Install washer (99), and bolt (102). Tighten to
the correct torque value. See page 92
5. Remove the outer control arm bracket (101),
bolt (107), washer (99), and inner control arm
bracket (105).
5. Install the spring (108).
105
12
101
109
109
13
106
99
99
107
104
102
103
110
108
Figure 1. PR Pump Return to Neutral
PR Series
93
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the bolt (102), washer (99) and bushing
(106).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket (101).
3. Remove bolt (107), washer (99) and the inner
control arm bracket (105).
2. Remove the fan nut and fan assembly (90).
3. Remove the bolts (56) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm (13) and trunnion arm seal
(12).
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2. Inspect bushing (106) and all other linkage parts
for damage, corrosion or wear.
Assembly
1. Install the inner return arm bracket (105),
washer (99) and bolt (107).
NOTE: Do not over tighten the bolt (107). The
bracket must move freely.
2. Install the outer control arm bracket (101),
bushing (106), washer (99), and bolt (102).
Tighten to the correct torque value. See page
92.
Assembly
1. To install the mounting bracket (209), align and
insert the bolts (56) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (56) per table 2, page
92.
2. Install the fan and washer assembly onto the
shaft.
3. Install the fan nut and tighten per table 2, page
92.
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
105
12
106
13
209
110
101
99
102
99
107
1
56
Figure 2. PR Pump Standard Control Arm
90
210
Figure 3. PR Pump Fan Assembly
94
PR Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
Refer to Figure 4.
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION
ARM (CONTROL ARM) SEAL
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (3) from housing (15).
2. Remove lip seal (6). Care must be taken to
prevent damage to the housing bore, shaft
sealing surface, or bearing. Once removed, the
seal is not reusable.
Inspection
1. Remove the retainer and lip seal (12) from the
housing (15). Care must be taken to prevent
damage to the housing trunnion bore, trunnion
arm (13) and sealing surface. Once removed
the retainer and lip seal is not reusable.
Inspection
1. With the lip seal (6) removed, inspect the spacer
(4), shaft bearing (5) and housing (15) bore.
1. With the lip seal (12) removed, inspect the area
for corrosion and wear. Inspect the trunnion bore
area sealing surface for damage or wear.
Assembly
Assembly
1. Lubricate the new lip seal (6) with petroleum
jelly.
1. Lubricate the new lip seal (12) with petroleum
jelly.
2. Wrap the input shaft (1) with plastic wrap to
prevent damage to the inner surface of the lip
seal (6).
2. Wrap the trunnion arm (13) with plastic wrap to
prevent damage to the inner surface of the lip
seal (12).
3. Slide the seal (6) over shaft (1) so that lettering
on the seal (6) faces out.
3. Slide the lip seal (12) over the trunnion arm (13)
so that the lettering on the seal (12) faces out.
4. Press the lip seal (6) into the housing (15) bore.
Insure seal (6), shaft (1) or housing (15) bore
do not become damaged.
4. Press the lip seal (12) into the housing bore
(15). Insure the seal (12), trunnion arm (13),
and housing bore do not become damaged.
Remove the plastic wrap.
5. Remove the plastic wrap.
6. Install the retaining ring (3) into the housing (15)
bore groove.
4
20
6
5. Install the retainer from (12) over the trunnion
arm (13) on top of the lip seal (12). Press into
the trunnion seal bore in the housing until the
retainer mates against the trunnion seal.
3
19
15
5
13
1
15
Figure 4. PR Pump Input Shaft Seal
12
Figure 5. PR Pump Trunnion Arm Seal
PR Series
95
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CHECK VALVES
Refer to Figure 6.
Disassembly
REMOVAL, INSPECTION AND/
OR REPLACEMENT OF SYSTEM
CHECK RELIEFS (SCR’S) OR
SHOCK VALVES
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary
in “A” side to “B” side check configuration.
Refer to Figure 7.
1. Remove the check valve (42) with an 1/4” allen
wrench.
Perform disassembly, inspection and assembly on
SCR/shock valve one side at a time. Some units
vary in “A” side to “B” side configuration.
2. Remove the valve spring and poppet from the
end cap (25).
Inspection
Disassembly
1. Remove the SCR (42) with a 7/8” wrench or the
shock valve (42) with an 11/16” wrench.
1. Inspect the poppets and mating seats in the end
cap (25) for damage or foreign material.
2. Remove the check relief/shock valve spring and
the check relief/shock valve from the end cap
(25).
Assembly
Inspection
1. Lay the pump on its side, so the check plug port
is horizontal.
1. Inspect the check relief or shock valve (42) and
mating seat in the end cap (25) for damage or
foreign material.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten,
reference Table 2, page 92 for torque values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42A
(PORT “A”
SIDE)
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve as
one assembly into the check plug port. Tighten
to the correct torque value. See page 92.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
25
42B
(PORT “B”
SIDE)
OR
42A
Figure 6. PR Pump Check Valves
OR
42B
25
Figure 7. PR Pump Shock Valves
96
PR Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (50) using a 5/8”
wrench.
2. Remove the bypass (50) from the end cap
(25).
Inspection
1. Inspect the bypass O-rings and mating seats
in the end cap (25) for damage or foreign
materials.
2. If damaged or worn replace bypass (50).
Assembly
1. Lay the pump on its side, so the bypass port is
horizontal.
2. Insert the bypass (50) into the bypass port on
the end cap (25). Tighten to the proper torque
value. See page 92.
25
50
Figure 8. PR Pump Bypass
PR Series
97
REMOVAL, INSPECTION AND
ASSEMBLY OF STANDARD OR
THRU SHAFT CHARGE PUMP
Assembly
Disassembly
1. Lubricate the new shaft seal with petroleum
jelly.
NOTE: For the Thru Shaft charge pump
follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Refer to Figure 9.
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Using a 1/2 inch wrench loosen the charge
pump cover bolts (56) from the end cap (2).
While holding the charge cover in place, remove
the charge cover bolts (56).
3. Remove the charge cover, O-ring (39) and
gerotor items (41). Carefully check for and
remove the charge spring and charge ball
(44).
2. Press the shaft seal into the charge cover. Be
careful not to damage the seal or charge cover
bore.
3. Position the pump with the input shaft down, and
the end cap (25) horizontal. Place the charge
ball (44) in the end cap (25) charge passage
so the ball mates to the end cap (25) charge
ball seat. Place the charge spring, on top of the
charge ball.
4. Insert the outer gerotor over input shaft.
4. For the Thru Shaft charge pump, remove the
shaft seal.
5. Align the outer gerotor to fit over the inner
gerotor.
Inspection
6. Insert the O-ring (39) into the groove in the
charge cover.
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap for
damage or foreign material.
NOTE: If the end cap (2) is to be removed from the housing, do not assemble the charge pump (40) until the
end cap is installed on the housing.
2. Inspect the charge cover bore for damage,
corrosion or wear.
7. Position the charge cover and O-ring (39) with
the aligning mark on the end cap (25). Place the
charge cover and O-ring with aligning mark on
the end cap. Place the charge cover and O-ring
as one piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(56) into the end cap (25). Tighten to the correct
torque value. See Table 2, page 92. (Torque
Values.)
44
THRU SHAFT
40
39
41
41
37
39
56
25
STANDARD
56
40
Figure 9. PR Pump Standard or Thru Shaft Charge Pump
98
PR Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
2. Inspect all O-rings, gasket and mounting
seats.
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 10.
Assembly
Disassembly
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
92.
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump, charge pump (41)
and end cap (25) for alignment at assembly.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (56) from the end cap (25). While
holding the auxiliary pump in place, remove the
bolts (56).
2. Install the poppet, spring and cap as one
assembly (49) into the charge relief port. Tighten
to the correct torque value. See page 92.
3. Install the filter (54) and O-ring onto the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
(156) into the filter cover (67). See page 92 for
the correct torque value.
3. Remove the auxiliary pump, gasket, O-ring (39)
and charge pump (41). While removing the
charge pump, be sure to retain the spring and
ball (44) housed in the end cap (25).
4. Remove the plug (156) from the filter cover
(67).
4. Lay the PR pump (input shaft down), so the end
cap is horizontal. Install the O-ring (39) into the
charge pump (41).
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the auxiliary pump.
5. Install the gasket onto the auxiliary pump.
6. Remove the O-ring and filter (54).
6. Make sure that the ball and spring (44) are
seated in the end cap (25), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (41). Insure that the pump
fully engages the alignment pins (69).
7. Remove the charge relief valve assembly (49)
and auxiliary relief valve assembly (45) from the
auxiliary pump.
Inspection
7. Align and insert the bolts (56) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (56) per
table 2, page 92.
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
44
40
69
41
39
39
49
45
54
25
168
67
56
1
158
156
168
Figure 10. PR Series Auxiliary Pump
PR Series
99
NOTE: Grooving in the valve plate and/or end
cap, made evident when the surface is checked
by dragging a fingernail across it, would be
cause for replacement of the valve plate.
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP AND
VALVE PLATE
Refer to Figure 11.
3. Inspect and replace alignment pins (26) if bent
or distorted.
Disassembly
1. Using any combination of two, 9/16” wrenches
or 9/16” socket and ratchet drive, loosen the
end cap bolts (58) evenly.
4. Replace the housing O-ring (28) with a new
O-ring before reassembly.
Assembly
2. Keeping the end cap (25) held in place, remove
the four end cap bolts (58).
1. Install O-ring (28) into the O-ring seat of housing
(15).
3. Slowly remove the end cap (25).
2. Install alignment pins (26) into housing (15).
4. Remove the valve plate (29).
3. Lubricate the valve plate prior to installation.
Install valve plate (29) so the bronze side of the
valve plate is facing down toward the cylinder
block.
NOTE: This step is only applicable on PR series
pumps built prior to 0216Pxxxxx.
5. Remove housing alignment pins (26).
6. Remove housing gasket (28).
NOTE: This step is only applicable on PR series pumps built prior to 0216Pxxxxx.
4. On pumps built without a valve plate, lubricate
the end cap (25) prior to installation.
Inspection
1. Inspect the end cap (25) body for damage,
nicks or unusual wear patterns. Replace if
necessary.
2. Inspect the running surface (side that contacts
the cylinder block) of the valve plate (29) and/
or end cap (25). The running surface may
show evidence of minor abrasive rings, this is
normal.
5. Install end cap (25). Before installing the four
end cap bolts (58), push down on the end cap
(25) verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install and torque end cap bolts (58). Reference
Table 2, page 92 (torque values).
On or After Serial # 0216Pxxxxx
Prior to Serial # 0216Pxxxxx
26
26
44
44
26
4X 58
29
15
26
28
4X 58
40
28
40
25
25
56
56
Figure 11. PR Pump End Cap
100
PR Series
15
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Assembly
Refer to Figure 12.
3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
Disassembly
1. Tilt the pump on its side, drain remaining oil. Lift
out the cylinder block assembly (38).
1. Install piston seats into the end of the pistons.
2. Install springs into the pistons.
4. With the pump housing tilted on its side, install
the cylinder block assembly (38) with pistons
contacting the thrust bearing.
2. Remove the pistons, springs and piston seats.
Inspection
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns.
The running surface may show evidence of
minor abrasion. This will be normal wear. If
grooved or smeared, replace with a new cylinder
block assembly.
2. Inspect the piston springs for distortion or
breaks. If necessary, replace with a new cylinder
block kit.
3. Inspect the piston seats. Residual oil may
cause these to remain stuck to the inside of the
pistons.
NOTE: To check that piston placement is
correct, push downward on the cylinder
block assembly (38). If this results in a
spring action the block assembly has
been installed correctly. If this cannot be
accomplished, remove and reassemble
the block assembly. Place a rubber band
around the cylinder block pistons to hold
them in position during installation. Then
after installation cut the rubber band and
remove it. Check cylinder block assembly for spring action.
Piston (x7)
Piston
Seat (x7)
Spring (x7)
Cylinder
Block
38
Figure 12. PR Pump Cylinder Block
PR Series
101
REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING,
THRUST WASHER, AND THRUST
BEARING
Refer to Figure 14.
Refer to Figure 13.
Disassembly
Disassembly
1. Remove the swashplate (31).
1. Remove the block spring (20).
Inspection
2. Remove the thrust washer (19).
1. Inspect the running surface of the bearing pocket
for damage (31), nicks or unusual wear patterns.
The running surface may show evidence of
minor abrasion. This is normal wear. Inspect
the cradle bearing side of the swashplate (31)
for damage. Replace if necessary.
3. Remove the thrust bearing and race (17).
Inspection
1. Inspect and replace the block spring (20)
and thrust washer (19) if they are distorted or
broken.
2. Inspect the running surface of the bearing race
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor
abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Assembly
1. Install thrust bearing and race assembly (17).
NOTE: The difference in race thicknesses: The thin race seats into the swashplate. The thicker race will be installed
toward the piston noses.
2. Install thrust washer (19).
REMOVAL, INSPECTION OF
SWASHPLATE, INSPECTION OF
CRADLE BEARINGS
2. Inspect the cradle bearings attached to the inside
of the housing (15) for normal wear patterns,
placement, and insure they are staked securely
in place. If damaged, replace housing (15).
NOTE: The cradle bearings will have
discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (31) by holding trunnion arm’s
(13) slot guide (14) with a flat tip screwdriver.
Use the screwdriver to hold the slot guide (14)
in place while positioning the swashplate (31)
onto the cradle bearing in the housing (15).
2. Rotate trunnion arm (13) to assure swashplate
pivoting action.
3. Install block spring (20).
31
17
20
19
19
17
14
13
20
15
(Cradle Bearings cannot be
removed from housing as depicted)
Figure 13. PR Pump Block Spring and
Thrust Bearing
102
Figure 14. PR Pump Swashplate and
Cradle Bearings
PR Series
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
delay reassembly of input shaft assembly.
Refer to Figure 15.
5. Inspect and replace the thrust spring (20)
and thrust washer (19) if they are distorted or
broken.
Assembly
Disassembly
1. Remove the retaining ring (3).
2. Remove the lip seal (6).
NOTE: Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
3. Remove the spacer (4).
4. Remove the shaft assembly (1).
Inspection
1. Inspect the input shaft (1) for worn splines,
damage, or keyway damage. Replace shaft
assembly if necessary.
2. Inspect the bearing (5) for evidence of scoring,
corrosion, or damage. Replace shaft assembly
if necessary.
3. Inspect and replace the spacer (4) if it is bent or
broken.
NOTE: Replace the input shaft seal (6)
after removal.
1. Install input shaft assembly (1) into the housing
(15) bore. Light tapping with a rubber mallet
may be necessary on the input shaft (1) once
the bearing is aligned with the housing bore
(15). Rotate the input shaft (1) to insure free
movement.
2. Install spacer (4).
3. Install new lip seal (6).
4. Inspect and replace the retaining ring (3) if it is
bent or broken.
4. Install retaining ring (3).
3
6
4
2
20
19
2
5
2
1
15
Figure 15. PR Pump Input Shaft
PR Series
103
REMOVAL AND INSPECTION OF
TRUNNION ARM
Refer to Figure 16.
Disassembly
1. Remove and discard the trunnion seal retainer
and seal (12).
2. Remove the slot guide (14).
NOTE: Upon removal, it is recommended
that all seals, O-rings, and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of seals
by covering the shaft with plastic wrap.
Remove the plastic wrap after the seal
is installed.
3. Remove the trunnion arm (13).
15
Inspection
1. Inspect the trunnion arm (13) for wear or damage.
Replace the trunnion arm if necessary.
Assembly
1. Install the trunnion arm (13) into the housing
(15) bore. Rotate the trunnion arm to verify free
movement.
2. Install a new seal and seal retainer (12).
3. Install the slot guide (14).
14
13
12
Figure 16. PR Pump Trunnion Arm
4. To completely reassemble the pump, refer to
the assembly steps on pages 93-104. Begin
with the trunnion arm assembly steps listed on
page 90 and complete the assembly steps in
reverse order working towards the front of the
manual.
104
PR Series
PR Series
105
Figure 17. PR Pump
106
PR Series
BOXES INDICATE ITEMS INCLUDED IN KITS.
Kit Number
ITEM LIST - PR SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No. Description
1
Pump Shaft Kit (19T spline)
Pump Shaft Kit (17 mm keyed)
Pump Shaft Kit (17 mm keyed thru taper)
Pump Shaft Kit (double tapered thru shaft)
3
Retaining Ring
4
Spacer
5
Shaft Ball Bearing
6
Lip Seal 17 X 47 X 8 PTCN1
12 Trunnion Seal Kit
13 Trunnion Arm
14 Slot Guide
15 Housing Kit
17 Thrust Ball Bearing Assembly
19 Block Thrust Washer
20 Block Spring
25 End Cap Kit (w/poppets & std chg)
End Cap Kit (w/poppets & aux chg)
26 Pin
28 O-Ring
29 Valve Plate
31 Variable Swashplate
38 Cylinder Block Kit (16cc)
39 O-Ring
R-Ring (-144)
40 Charge Pump Kit (.19 std splined)
Charge Pump Kit (.13 std thru shaft)
Charge Pump Kit (CW-Iron Aux, 40-70 psi,
.001” shim)
Charge Pump Kit (CW-Iron Aux, 135-165 psi,
.001” shim)
Charge Pump Kit (CCW-Iron Aux, 70-70 psi,
.001” shim)
Charge Pump Kit (Al Aux, 7/16 SAE port,
40-70 psi, .001” shim)
Charge Pump Kit (Al Aux 7/16 SAE port,
75-105 psi, .001” shim)
41 Gerotor Assembly (.13 cu.in./rev)
Gerotor Assembly (.19 cu.in./rev)
Aux Gerotor & Hsg Assembly (0.19 cu.in./
rev)
42 Check Valve Kit (blank orifice)
Check Valve Kit (0.24” orifice)
Check Valve Kit (.031” orifice)
Check Valve Kit (.044” orifice)
Shock Valve Kit (blank orifice)
Shock Valve Kit (.024” orifice)
PR Series
No. Description
Shock Valve Kit (.031” orifice)
Shock Valve Kit (.044” orifice)
44 Charge Relief Kit (1/4” plastic ball & spring)
Charge Relief Kit (1/4” plastic ball & spring)
Charge Relief Kit (w/ 9/16” SAE valve plug
40-70 psi)
Charge Relief Kit (w/ 9/16” SAE valve plug
75-105 psi)
Charge Relief Kit (w/ 1/2” SAE valve plug
40-70 psi)
Charge Relief Kit (w/ 1/2” SAE valve plug
135-1650 psi)
45 Aux Relief Valve Kit
49 Aux Bypass/Check Kit
50 Bypass Valve Kit (blank orifice)
Bypass Valve Kit (.031” orifice)
Bypass Valve Kit (.043” orifice)
54 Auxiliary Filter Kit
56 Socket Hd Cap Screw (M8 x 1.25-25mm
Flange Hd Screw (5/16-18 x 2.5)
58 Hex Screw, Flanged Hd (M10 x 1.50-65 mm)
60 Mounting Bracket
67 Filter Cover
69 Dowel Pin
90 Fan Kit
99 Washer
100 Seal Kit
101 Control Arm
102 Screw
103 Outer Scissor Arm
104 Inner Scissor Arm
105 Return Arm
106 Spacer
197 Screw
108 Spring
109 Washer
110 Return Kit
149 Plug
150 Plug
151 Plug
152 Plug
153 Plug
156 Plug
158 Plug
168 Connector
209 Shroud Bracket
210 Shroud
107
108
PR Series
REPAIR - PW SERIES PUMP
Repair - PW Series Pump.................................................................................................. 109-126
How to Use This Manual............................................................................................................109
General Instructions...................................................................................................................109
Tools and Torques......................................................................................................................110
Return to Neutral Linkage........................................................................................................... 111
Standard Control Arm Linkage...................................................................................................112
Fan Assembly.............................................................................................................................112
Input Shaft Seal..........................................................................................................................113
Trunnion Arm Seal......................................................................................................................113
Check Valves..............................................................................................................................114
Shock Valves..............................................................................................................................114
Bypass........................................................................................................................................115
Charge Pump-Standard or Thru Shaft........................................................................................116
Auxiliary Pump............................................................................................................................117
End Cap......................................................................................................................................118
Cylinder Block.............................................................................................................................119
Block Spring and Thrust Bearings..............................................................................................120
Swashplate and Cradle Bearings...............................................................................................120
Input Shaft..................................................................................................................................121
Trunnion Arm..............................................................................................................................122
Parts List............................................................................................................................. 124-125
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded
view showing the parts involved. The item
reference numbers in each illustration are for
assembly instructions only. See pages 124 and
125 for part names and descriptions. A complete
exploded view and item list of the pump is provided
at the end of this section.
Lip-type seals (shaft seals) are used on the input
shaft and directional control shaft of each Pump.
These seals can be replaced without major disassembly of the unit. However, replacement of these
seals generally requires removal of the pump from
the machine. Upon removal, it is recommended that
all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS
During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior
to assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane (plastic
wrap, etc.) material.
Cleanliness is a primary means of ensuring
satisfactory life on repaired pumps. Thoroughly
clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with any
precision equipment, all parts must be kept free of
foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PW Series
Parts requiring replacement must be replaced from
the appropriate kits identified in the Items Listing,
found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN51427 (CD).
109
TOOLS AND TORQUES
Miscellaneous
3/8-Inch Drive Ratchet and Sockets
P Series Service & Repair Manual
1/2-inch Socket
Torque Wrench
9/16-inch Socket
Scribe, Paint Pen, or Marker
5/8-inch Socket
Seal Hook with a Magnet
10-mm Socket
Flat Blade Screwdriver
Combination Wrenches
Pliers
1/2 inch
Internal Snap Ring
9/16 inch
5/8 inch
Allen Wrenches
7/8 inch
5mm
10 mm
3/16 inch
1/4 inch
Table 1. Required Tools
Item # and/or Description
Torque
Case Drain (fitting torque)
System Port (fitting torque)
Inlet (fitting torque)
Fan Nut, Hex Lock 3/8-24 UNF
42A, 42B, Shock Valves/Check Plugs
44, Charge Relief Kit
45, Aux Relief Valve Kit
49, Aux Bypass/Check Kit
50, Bypass Valve
56, Screw
58, Housing Bolt
66, Steel Plug
67, Filter Cover
Screw, Socket Hd.Control Arm 5/16-24 x .75
Screw, Socket Hd. RTN M8 x 1.25 x 25
370-470 lb-in (41.8-53.1 Nm)
370-470 lb-in (41.8-53.1 Nm)
370-470 lb-in (41.8-53.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
180-240 lb-in (20.3-27.1 Nm)
84-120 lb-in (9.4-13.5 Nm)
180-220 lb-in (20.3-24.9 Nm)
255-345 lb-in (28.8-38.9 Nm)
55-85 lb-in (6.2-9.6 Nm)
200-275 lb-in (22.6-31.1 Nm)
200-240 lb-in (22.6-27.1 Nm)
180-220 lb-in (20.3-24.9 Nm)
Table 2. PW Pump Torque Values
110
PW Series
PW SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control
arm bracket.
See Figure 1.
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm and trunnion arm seal.
2. Inspect bushing (116) and all other linkage parts
for damage, corrosion or wear.
Disassembly
CAUTION: The spring used on the return to neutral
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly
and assembly of the return to neutral linkage.
Assembly
1. Loosen (but do not remove) the bolt (112).
NOTE: Do not over tighten the bolt (117). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from
the tab on the outer control arm bracket.
3. Remove the spring (18), bolt (112) washer (109)
and outer scissor arm bracket (113).
4. Remove bushing (116), washer (119), and the
inner scissor control arm bracket (114).
5. Remove the outer control arm bracket (111),
bolt (117), washer (109), and inner control arm
bracket (115).
1. Install the inner control arm bracket (115),
washer (109) and bolt (117).
2. Install the outer control arm bracket (111),
washer (119) and bushing (116).
3. Install the inner scissor arm bracket (114),
washer (119), and outer scissor arm bracket
(113).
4. Install washer (109), and bolt (112). Tighten to
the correct torque value. See page 110.
5. Install the spring (18).
110
109
116
112
119
113
117
119
109
18
114
111
115
Figure 1. PW Pump Return to Neutral
PW Series
111
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2.
Refer to Figure 3.
Disassembly
Disassembly
1. Remove the bolt (112), washer (109) and
bushing (116).
1. Remove the fan shroud (210) from the mounting
bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket (111).
3. Remove bolt (117), washer (109) and the inner
control arm bracket (115).
2. Remove the fan nut and fan assembly (90).
3. Remove the bolts (56) and bracket (209).
Inspection
Inspection
1. With the arm control linkage removed, inspect
the trunnion arm and trunnion arm seal.
Inspect the fan shroud (210), fan assembly (90) and
mounting bracket (209) for damage.
2. Inspect bushing (116) and all other linkage parts
for damage, corrosion or wear.
Assembly
1. Install the inner return arm bracket (115),
washer (109) and bolt (117).
1. To install the mounting bracket (209), align and
insert the bolts (56) into the bracket and charge
pump cover. While holding the charge cover in
place, tighten the bolts (56) per table 2, page
110.
NOTE: Do not over tighten the bolt (117). The
bracket must move freely.
2. Install the fan and washer assembly onto the
shaft.
2. Install the outer control arm bracket (111),
bushing (116), washer (109) and bolt (112).
Tighten to the correct torque value. See page
110.
3. Install the fan nut and tighten per table 2, page
110.
Assembly
110
112
116
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
117
209
109
109
111
115
56
Figure 2. PW Pump Standard Control Arm
90
210
Figure 3. PW Pump Fan Assembly
112
PW Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF INPUT SHAFT
SEAL
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF TRUNNION
ARM (CONTROL ARM) SEAL
Refer to Figure 4.
Refer to Figure 5.
Disassembly
Disassembly
1. Remove retaining ring (3) from housing (15).
1. Remove the retainer and lip seal (12). Care
must be taken to prevent damage to the housing
trunnion bore, trunnion arm (13) and sealing
surface. Once removed the retainer and lip seal
(12) is not reusable.
2. Remove lip seal (6). Care must be taken to
prevent damage to the housing bore, shaft,
sealing surface, or bearing. Once removed, the
seal is not reusable.
Inspection
Inspection
1. With the lip seal (6) removed, inspect the spacer
(4), shaft bearing (5) and housing (15) bore.
1. With the lip seal (12) removed, inspect the area
for corrosion and wear. Inspect the trunnion bore
area sealing surface for damage or wear.
Assembly
Assembly
1. Lubricate the new lip seal (6) with petroleum
jelly.
1. Lubricate the new lip seal (12) with petroleum
jelly.
2. Wrap the input shaft (1) with plastic wrap to
prevent damage to the inner surface of the lip
seal (6).
2. Wrap the trunnion arm (13) with plastic wrap to
prevent damage to the inner surface of the lip
seal (12).
3. Slide the seal (6) over shaft (1) so that lettering
on the seal (6) faces out.
3. Slide the lip seal (12) over the trunnion arm (13)
so that the lettering on the seal (12) faces out.
4. Press the lip seal (6) into the housing (15) bore.
Insure seal (6), shaft (1) or housing (15) bore
do not become damaged. Remove the plastic
wrap.
4. Press the lip seal (12) into the housing bore
(15). Insure the seal (12), trunnion arm (13),
and housing bore do not become damaged.
Remove the plastic wrap.
5. Install the retaining ring (3) into the housing (15)
bore groove.
5. Install the retainer over the trunnion arm (13) on
top of the lip seal (12). Press into the trunnion
seal bore in the housing (15).
6
3
5
15
12
4
15
1
Figure 4. PW Pump Input Shaft Seal
13
Figure 5. PW Pump Trunnion Arm Seal
PW Series
113
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CHECK VALVES
Refer to Figure 6.
Disassembly
REMOVAL, INSPECTION AND/
OR REPLACEMENT OF SYSTEM
CHECK RELIEFS (SCR’S) OR
SHOCK VALVES
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary
in “A” side to “B” side check configuration.
Refer to Figure 7.
1. Remove the check valve (42) with an 1/4” allen
wrench.
Perform disassembly, inspection and assembly on
SCR/shock valve one side at a time. Some units
vary in “A” side to “B” side configuration.
2. Remove the valve spring and poppet from the
end cap (25).
Inspection
Disassembly
1. Remove the SCR (42) with a 7/8” wrench or the
shock valve (42) with an 11/16” wrench.
1. Inspect the poppets and mating seats in the end
cap (25) for damage or foreign material.
2. Remove the check relief/shock valve spring and
the check relief/shock valve from the end cap
(25).
Assembly
Inspection
1. Lay the pump on its side, so the check plug port
is horizontal.
1. Inspect the check relief or shock valve (42) and
mating seat in the end cap (25) for damage or
foreign material.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten,
reference Table 2, page 110 for torque values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42B
Assembly
1. Lay the pump on its side, so the check plug port
is horizontal.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve
as one assembly into the check plug port.
Tighten, reference Table 2, page 110, for torque
values.
3. Repeat disassembly, inspection and assembly
for the opposite port side.
42A
42B
OR
25
42B
Figure 6. PW Pump Check Valves
42A
OR
42A
Figure 7. PW Pump Shock Valves
114
PW Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (50) using a 5/8”
wrench.
2. Remove the bypass (50) from the end cap
(25).
Inspection
1. Inspect the bypass O-rings and mating seats
in the end cap (25) for damage or foreign
materials.
2. If damaged or worn replace bypass (50)
Assembly
1. Lay the pump on its side, so the bypass port is
horizontal.
2. Insert the bypass (50) into the bypass port on
the end cap (25). Tighten, reference Table 2,
page 110, torque values.
50
25
Figure 8. PW Pump Bypass
PW Series
115
REMOVAL, INSPECTION AND
ASSEMBLY OF STANDARD OR
THRU SHAFT CHARGE PUMP
Refer to Figure 9.
Assembly
NOTE: For the Thru Shaft charge pump
follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Disassembly
1. Lubricate the new shaft seal with petroleum
jelly.
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment
at assembly.
2. Press the shaft seal into the charge cover. Be
careful not to damage the seal or charge cover
bore.
2. Using a 1/2 inch wrench loosen the charge
pump cover bolts (56) from the end cap (25).
While holding the charge cover in place, remove
the charge cover bolts (56).
3. Position the pump with the input shaft down, and
the end cap (25) horizontal. Place the charge
ball (44) in the end cap (25) charge passage
so the ball mates to the end cap (25) charge
ball seat. Place the charge spring, on top of the
charge ball.
3. Remove the charge cover, O-ring (39) and
gerotor items (41). Carefully check for and
remove the charge spring and charge ball
(44).
4. For the Thru Shaft charge pump, remove the
shaft seal.
Inspection
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check
ball (44), and mating seat in the end cap (25)
for damage or foreign material.
NOTE: If the end cap (25) is to be removed from the housing, do not assemble the charge pump (40) until the
end cap is installed on the housing.
2. Inspect the charge cover bore for damage,
corrosion or wear.
4. Insert the inner gerotor over input shaft.
5. Align the outer gerotor to fit over the inner
gerotor.
6. Insert the O-ring (39) into the groove in the
charge cover.
7. Position the charge cover and O-ring (39) with
the aligning mark on the end cap (25). Place the
charge cover and O-ring with aligning mark on
the end cap. Place the charge cover and O-ring
as one piece over the charge spring (44) and
gerotor assembly. Insure the spring fits into the
charge cover spring retaining groove.
8. Align and insert the charge pump cover bolts
(56) into the end cap (25). Tighten to the correct
torque value. See Table 2, page 110. (Torque
Values.)
44
THRU SHAFT
41
40
39
37
39
25
41
56
56
40
STANDARD
Figure 9. PW Pump Standard or Thru Shaft Charge Pump
116
PW Series
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED)
2. Inspect all O-rings, gasket and mounting
seats.
3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
Refer to Figure 10.
Assembly
Disassembly
1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Tighten to the correct torque value. See page
110.
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump, charge pump (41)
and end cap (25) for alignment at assembly.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (56) from the end cap (25). While
holding the auxiliary pump in place, remove the
bolts (56).
2. Install the poppet, spring and cap as one
assembly (44) into the charge relief port. Tighten
to the correct torque value. See page 110.
3. Install the filter (54) and O-ring into the filter
cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install the
plug (66) into the filter cover (67).
3. Remove the auxiliary pump, gasket, O-ring (39)
and charge pump (41). While removing the
charge pump, be sure to retain the spring and
ball (44A) housed in the end cap (25).
4. Lay the PW pump (input shaft down), so the end
cap is horizontal. Install the O-ring (39) into the
charge pump (41).
4. Remove the plug (66) from the filter cover
(67).
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the pump.
5. Install the gasket onto the auxiliary pump.
6. Make sure that the ball and spring (44A) are
seated in the end cap (25), then position the
auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
fully engages the alignment pins (69).
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44)
and auxiliary relief valve assembly (45) from the
auxiliary pump.
7. Align and insert the bolts (56) into the auxiliary
pump. While holding the auxiliary pump and
charge pump in place, tighten the bolts (56) per
table 2, page 110.
Inspection
1. With the auxiliary pump removed, inspect the
pump running surfaces for wear or damage.
168
44A
40
45
44
39
41
66
39
69
67
54
1
25
(2X) 56
Figure 10. PW Series Auxiliary Pump
PW Series
117
REMOVAL, INSPECTION AND
ASSEMBLY OF THE END CAP AND
VALVE PLATE
Refer to Figure 11.
NOTE: Grooving in the valve plate and/or
end cap, made evident when the surface is
checked by dragging a fingernail across the
surface, would be cause for replacement of
the valve plate and/or end cap.
2. Inspect and replace alignment pins (26) if bent
or distorted.
Disassembly
1. Using any combination of two, 9/16” wrenches
or 9/16” socket and rachet drive, loosen the end
cap bolts (58) evenly.
2. Keeping the end cap (25) held in place, remove
the four end cap bolts (58).
3. Slowly remove the end cap (25).
3. Replace the housing O-ring (28) with a new
O-ring before reassembly.
Assembly
1. Install housing O-ring (28) into O-ring seat of
housing (15).
2. Install alignment pins (26) into housing (15).
4. Remove the valve plate (29).
NOTE: This step is only applicable on PW series
pumps built prior to 0216Pxxxxx.
3. Lubricate the valve plate prior to installation.
Install valve plate (29) with the bronze side
down, contacting the cylinder block.
5. Remove housing alignment pins (26).
6. Remove housing gasket (28).
NOTE: This step is only applicable on PW
series pumps built prior to 0216Pxxxxx.
4. On pumps built without a valve plate, lubricate
the end cap prior to installation.
Inspection
1. Inspect the end cap (25) and/or valve plate (29)
for damage, nicks or unusual wear patterns.
Prior to Serial # 0216Pxxxxx
5 Install end cap (25). Before installing the four
end cap bolts (58), push down on the end cap
(25) verifying alignment and insuring that the
cylinder block pistons spring back and forth.
Install end cap bolts. Tighten, per Table 2, page
110, torque values.
On or After Serial # 0216Pxxxxx
15
15
26
26
29
26
26
28
28
(4X) 58
25
(4X) 58
25
Figure 11. PW Pump End Cap
118
PW Series
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER
BLOCK
Assembly
Refer to Figure 12.
3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
Disassembly
1. Tilt the pump on its side, drain remaining oil. Lift
out the cylinder block assembly (38).
2. Remove the pistons, springs and piston seats.
Inspection
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns.
The running surface may show evidence of
minor abrasion. This will be normal wear. If
grooved or smeared, replace with a new cylinder
block assembly.
2. Inspect the piston springs for distortion or
breakage. If necessary, replace with a new
cylinder block kit.
1. Install piston seats into the end of the pistons.
2. Install springs into the pistons.
4. With the pump housing tilted on its side, install
the cylinder block assembly (38) with pistons
contacting the thrust bearing.
NOTE: To check that piston placement is
correct, push downward on the cylinder
block assembly (38). If this results in a
spring action the block assembly has
been installed correctly. If this cannot be
accomplished, remove and reassemble
the block assembly. Place a rubber band
around the cylinder block pistons to hold
them in position during installation. Then
after installation cut the rubber band and
remove it. Check for cylinder block assembly for spring action.
3. Inspect the piston seats. Residual oil may
cause these to remain stuck to the inside of the
pistons.
Spring (7X)
Cylinder Block
Piston (7X)
Piston
Seat (7X)
38
Figure 12. PW Pump Cylinder Block
PW Series
119
REMOVAL, INSPECTION AND
ASSEMBLY OF THRUST BEARING
Refer to Figure 13.
REMOVAL, INSPECTION AND
ASSEMBLY OF SWASHPLATE AND
CRADLE BEARINGS
Disassembly
Refer to Figure 14.
1. Remove the thrust bearing and race (17).
Disassembly
Inspection
1. Remove the swashplate (31).
1. Inspect the running surface of the bearing race
for damage (17), nicks or unusual wear patterns.
The running surface may show evidence of
minor abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage.
Replace if necessary.
Inspection
Assembly
1. Install thrust bearing and race assembly (17).
NOTE: The difference in race thicknesses: The thin race seats into the swashplate. The thicker race will be installed
toward the piston noses.
1. Inspect the running surface of the bearing pocket
for damage (31), nicks or unusual wear patterns.
The running surface may show evidence of
minor abrasion. This is normal wear. Inspect
the cradle bearing side of the swashplate (31)
for damage. Replace if necessary.
2. Inspect the cradle bearings attached to the inside
of the housing (15) for normal wear patterns,
placement, and insure they are staked in place.
If damaged, replace housing (15).
NOTE: The cradle bearings will have
discoloration due to normal wear. Under
normal circumstances, this will not warrant replacement.
Assembly
1. Install swashplate (31) by holding trunnion arm’s
(13) slot guide (14) with a flat tip screwdriver.
Use the screwdriver to hold the slot guide (14)
in place while positioning the swashplate (31)
onto the cradle bearing in the housing (15).
17
2. Rotate trunnion arm (13) to assure swashplate
pivoting action.
Figure 13. PW Pump Thrust Bearing
13
14
31
17
15
(Cradle Bearings cannot be
removed from housing as depicted)
Figure 14. PW Pump Swashplate and
Cradle Bearings
120
PW Series
REMOVAL, INSPECTION AND
ASSEMBLY OF INPUT SHAFT
Refer to Figure 15.
NOTE: If trunnion arm is to be removed,
delay reassembly of input shaft assembly.
5. Inspect and replace the thrust spring (20)
and thrust washer (19) if they are distorted or
broken.
Assembly
Disassembly
1. Remove the retaining ring (3).
2. Remove the lip seal (6).
3. Remove the spacer (4).
4. Remove the shaft assembly (1).
Inspection
1. Inspect the input shaft (1) for worn splines,
damage, or keyway damage. Replace shaft
assembly if necessary.
2. Inspect the bearing (5) for evidence of scoring,
corrosion, or damage. Replace shaft assembly
if necessary.
3. Inspect and replace the spacer (4) if it is bent or
broken.
NOTE: Replace the input shaft seal (6)
after removal.
4. Inspect and replace the retaining ring (3) if it is
bent or broken.
NOTE: Upon removal, it is recommended
that all seals, O-rings and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. Install input shaft (1) assembly into the housing
(15) bore. Light tapping with a rubber mallet
may be necessary on the input shaft (1) once
the bearing is aligned with the housing bore
(15). Rotate the input shaft (1) to insure free
movement.
2. Install spacer (4).
3. Install new lip seal (6). Remove the plastic
wrap.
4. Install retaining ring (3).
3
6
5
4
2
19
15
2
20
1
Figure 15. PW Pump Input Shaft
PW Series
121
REMOVAL AND INSPECTION OF
TRUNNION ARM
Refer to Figure 16.
15
Disassembly
12
1. Remove trunnion seal retainer and seal (12).
2. Remove the slot guide (14).
3. Remove the trunnion arm (13).
Inspection
1. Inspect the trunnion arm (13) for wear or damage.
Replace the trunnion arm if necessary.
Assembly
1. Install the trunnion arm (13) into the housing
(15) bore. Rotate the trunnion arm to verify free
movement.
14
13
Figure 16. PW Pump Trunnion Arm
NOTE: Upon removal, it is recommended
that all seals, O-rings, and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of seals
by covering the shaft with plastic wrap.
Remove the plastic wrap after the seal
is installed.
2. Install a new seal and seal retainer.
3. Install the slot guide (14).
4. To completely reassemble the pump, refer to
the assembly steps on pages 111-122. Begin
with the trunnion arm assembly steps listed on
page 122 and complete the assembly steps in
reverse order working towards the front of the
manual.
122
PW Series
PW Series
123
Figure 17. PW Pump
124
PW Series
BOXES INDICATE ITEMS INCLUDED IN KITS.
Kit Number
85- Overhaul Seal Kit
ITEM LIST - PW SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No. Description
1
Pump Shaft Kit (19T spline)
Pump Shaft Kit (closed key)
Pump Shaft Kit (thru shaft spline)
Pump Shaft Kit (tapered thru shaft)
Pump Shaft Kit (shaft - thru pump)
Retaining Ring
4
Spacer
5
Shaft Ball Bearing
6
Lip Seal 17 X 47 X 8 PTCN1
10 Trunnion Seal Retaining Ring
12 Lip Seal 15 X 27 X 7
13 Trunnion Arm
14 Slot Guide
15 Housing Kit
17 Thrust Ball Bearing Assembly
19 Block Thrust Washer
20 Block Spring
25 End Cap Kit (w/poppets)
End Cap Kit (w/poppets , .078” cooling ori
fice)
End Cap Kit (w SCR’S)
End Cap Kit (Aux w/ poppets)
End Cap Kit (Aux w/ SCR’s)
End Cap Kit (Aux w/ LH:SCR and RH:poppet)
End Cap Kit (w/LH:poppet and RH:SCR)
26 Pin
28 O-Ring
29 Valve Plate
31 Variable Swashplate
38 Cylinder Block Kit
39 O-Ring
R-Ring (-144)
40 Charge Pump Kit (0.19 std splined)
Charge Pump Kit (0.13 std splined)
Charge Pump Kit (0.13 std thru shaft)
Charge Pump Kit (0.13 std spline,
clear zinc cover)
Charge Pump Kit (CW - splined Aux, 40-70
psi)
Charge Pump Kit (CW - splined Aux,
135-165 psi)
Charge Pump Kit (CCW - splined Aux, 40-70
psi)
Charge Pump Kit (AL Aux, 7/16 SAE port,
40-70 psi)
PW Series
No. Description
Charge pump Kit (AL Aux, 7/16 SAE port,
75-105 psi)
41 Gerotor Assembly (0.19 in3/rev)
Aux Gerotor & HSG Assembly (0.19 in3/rev)
Gerotor Assembly (0.13 in3/rev)
42 Check Valve Kit (.031”)
Check Valve Kit (.044”)
Shock Valve Kit (blank)
System Check/Relief Kit
44 Charge Relief Kit (w 1/2” SAE valve plug,
40-70 psi)
Charge Relief Kit (w 1/2” SAE valve plug,
135-165 psi)
Charge Relief Kit (w/ 9/16” SAE valve plug)
Charge Relief Kit (w/ 9/16” SAE valve plug
75-105 psi)
Charge Relief Kit (w/ 7/32” plastic ball & spring)
Charge Relief Kit (w/ 1/4” plastic ball & spring)
45 Aux Relief Valve Kit
49 Aux Bypass/Check Kit
50 Bypass Valve Kit (blank)
Bypass Valve Kit (.031”)
54 Auxiliary Filter Kit
56 Hex Screw, 5/16 - 18 X 1.0
Hex Hd Cap Screw, 5/16 - 18 X 2.5
58 Hex Screw, Flanged Head
59 Hex Flange Nut
60 Mounting Bracket
66 Plug
67 Filter Cover
69 Pin
85 Overhaul Seal Kit
110 Return Kit
168 Connector
209 Shroud Bracket
210 Shroud
125
126
PW Series
GLOSSARY OF TERMS
Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged
parallel with the spindle (input or output shaft).
Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor
or pump. Also referred to occasionally as the freewheel valve or dump valve.
Case Drain Line (Return Line): A line returning fluid from the component housing to the reservoir.
Cavitation: A phenomenon of boiling in a flowing liquid at normal temperatures, as a result of low
pressure condition. The gas liberated from the fluid implodes rapidly and damages pump components.
Center Section: A device which acts as the valve body and manifold of the transmission.
Charge Pump: A device which supplies replenishing fluid to the fluid power system (closed
loop).
Charge Pressure: The pressure at which replenishing fluid is forced into a fluid power system.
Charge Relief Valve: A pressure control valve whose primary function is to limit pressure in the
charge circuit.
Check Valve: A valve whose primary function is to restrict flow in one direction.
Closed Loop: A sealed and uninterrupted circulating path for fluid flow from the pump to the
motor and back.
Decay Rate: The ratio of pressure decay over time.
End Cap: See “Center Section.”
Entrained Air: A mechanically generated mixture of air bubbles having a tendency to separate
from the liquid phase.
Gerotor: A fixed displacement pump frequently used as a charge pump.
Hydraulic Motor: A device which converts hydraulic fluid pressure and flow into mechanical
force and motion.
Hydraulic Pump: A device which converts mechanical force and motion into hydraulic fluid pressure and flow.
Hydrostatic Motor: See “Hydraulic Motor.”
Hydrostatic Pump: See “Hydraulic Pump.”
Hydrostatic Transaxle: A multicomponent assembly including a gear case and a hydrostatic
transmission.
P Series
127
Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to
form a device for the control and transfer of power.
Inlet Line: A supply line to the pump.
Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission and
gear case in one housing to form a complete transaxle.
Manifold: A conductor which provides multiple connection ports.
Neutral: Typically described as a condition in which fluid flow and system pressure are below
that which is required to turn the output shaft of the motor.
Pressure Decay: A falling pressure.
Priming: The filling of the charge circuit and closed loop of the fluid power system during
start-up, frequently achieved by pressurizing the fluid in the inlet line.
Purging: The act of replacing air with fluid in a fluid power system.
Rated Flow: The maximum flow that the pump is capable of supplying.
Scoring: Scratches in the direction of motion of mechanical parts caused by abrasive contaminants.
Shock Valve: A relief valve in the closed loop of the hydrostatic circuit that provides makeup oil,
as well as protecting the circuit from high pressure shocks or spikes.
Swashplate: A mechanical device used to control the displacement of the pump pistons in a fluid
power system.
System Charge Check Valve: A valve controlling the replenishing flow of fluid from a charge
circuit to the closed loop in a fluid power system.
System Pressure: The pressure which overcomes the total resistance in a system, including all
efficiency losses.
Valve: A device which controls fluid flow direction, pressure, or flow rate.
Variable Displacement Pump: A pump in which the displacement per revolution can be varied.
Volumetric Displacement: The fluid volume for one revolution.
128
P Series
© 2010 HYDRO-GEAR
Printed in U.S.A.
Rev. P3
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