Cub Cadet P Series User Manual

PK

PW

PG/PE

PC

PR

PJ

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 Specications ..............................................................................................................................11

Product Identication ................................................................................................................................. 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!

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 rep air procedures illustrated in this guide are suggested, but preferred methods of repair .

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.

iv

P Series

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.

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 specications, 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.

GENERAL DESCRIPTION

The P Series Pumps can be combined with wheel motors and other remotely located units. These

pumps provide an innitely 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 ow and/or direction.

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.

Additionally, some pumps may be equipped with an Auxiliary Pump. The Auxiliary incorporates the principles of the charge gerotor assembly and pro-

vides the capability of an external auxiliary ow for

an alternate hydraulic circuit to operate accessories without loss of drive.

Reversing the direction of the angle of the swash-

plate reverses the ow 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 lter is pumped into the closed loop

by a charge pump. Fluid not required to replenish

the closed loop ows either into the pump housing through a cooling orice, 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 ow for the system. The size and type of check valve can play an im-

portant role on the system pressure, response, and amount of heat generated, due to the recirculation

of makeup oil ow. Shock valves are factory preset pressure regulating check valves.

1P Series

EXTERNAL FEATURES - PC SERIES

Figure 1. PC Pump with Standard Charge Pump

2 P Series

EXTERNAL FEATURES - PG SERIES

SAE “A” PAD

FLANGE STYLE

STANDARD CHECK

VALVE OR SCR

CASE DRAIN

OPTION

“A” and “B”

PORTS

CHARGE

COVER

BYPASS VALVE

CHARGE PRESSURE DIAGNOSTIC PORT

STANDARD CHECK

VALVE OR SCR

INLET

INPUT SHAFT

TRUNNION

ARM

CASE DRAIN

OPTION

Figure 2. PG Pump With Standard Charge Pump

3P Series

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

5P Series

EXTERNAL FEATURES - PR SERIES

BYPASS

VALVE

SAE “A” PAD

FLANGE STYLE

TRUNNION ARM

INPUT SHAFT

CHARGE PRESSURE

DIAGNOSTIC PORT

“A” and “B” PORTS

SYSTEM CHECK VALVE

OR SHOCK VALVE

CASE DRAIN

BYPASS VALVE

CHARGE

COVER

INLET

SYSTEM CHECK VALVE

OR SHOCK VALVE

CASE DRAIN

Figure 4. PR Pump With Standard Charge Pump

6 P Series

EXTERNAL FEATURES - PW SERIES

SAE “B” PAD

FLANGE STYLE

TRUNNION ARM

INPUT SHAFT

BYPASS VALVE

“A” and

“B”

PORTS

CASE DRAIN

CHARGE PRESSURE DIAGNOSTIC PORT

STANDARD CHECK VALVE

OR SHOCK VALVE

Figure 5. PW Pump With Standard Charge Pump

CHARGE COVER

STANDARD CHECK VALVE

OR SHOCK VALVE

7P Series

HYDRAULIC SCHEMATIC

System Check & Relief Valve Options

Orice size

No Bleed .024 Bleed .031 Bleed .044 Bleed

Relief pressure (psi)

Check ball

1740 2320 2900

Relief pressure (bar)

Check ball

120 160 200

SYSTEM CHARGE RELIEF

CHARGE PUMP INLET

CHARGE DIAGNOSTIC

OR

PORT “A”

PORT “B”

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

Orice size

No Bleed .024 Bleed .031 Bleed .044 Bleed

Relief pressure (psi)

Check ball

1740 2320 2900

AUXILIARY DISCHARGE

Relief pressure (bar)

Check ball

120 160 200

AUXILIARY RETURN

650 PSI AUX RELIEF

SYSTEM CHARGE

RELIEF

OR

PORT “A”

PORT “B”

CHARGE PUMP INLET

CHARGE DIAGNOSTIC

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

Orice size

No Bleed .024 Bleed .031 Bleed .044 Bleed

Relief pressure (psi)

Check ball

1740 2320 2900

Relief pressure (bar)

Check ball

120 160 200

OR

PORT “A”

PORT “B”

System Check & Relief Valve Options

Orice size

No Bleed .024 Bleed .031 Bleed .044 Bleed

Relief pressure (psi)

Check ball

1740 2320 2900

AUXILIARY DISCHARGE

CHARGE DIAGNOSTIC

CHARGE PUMP INLET

Figure 8. PW Series Pump With Standard Charge Pump

Relief pressure (bar)

Check ball

120 160 200

AUXILIARY RETURN

AUXILIARY DISCHARGE

AUXILIARY RETURN

650 PSI

CHG REL

OR

BYPASS VALVE BLEED OPTIONS

1) NO BLEED ORIFICE

2) .031” BLEED ORIFICE

PORT “A”

CHARGE

CHARGE PUMP

DIAGNOSTIC

INLET

Figure 9. PW Series Pump With Auxiliary Charge Pump

PORT “B”

BYPASS VALVE BLEED OPTIONS

1) NO BLEED ORIFICE

2) .031” BLEED ORIFICE

9P Series

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 lter by the charge pump. The lter prevents contaminants

within the reservoir from entering into the charge pump gerotor.

The charge pump supplies uid to keep the closed

loop pressurized, preventing cavitation and provid-

ing cooling oil ow for the system.

The charge relief valve is used to maintain charge at a predetermined pressure.

Output of the system oil ow 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).

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 ow. During the operation of the pump, uid 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” uid returns to the reservoir through the case drain. This uid must be made up in the loop. The charge pump makes up this uid loss.

The makeup ow is controlled (or directed) by the system check valves. The check valves are used to direct makeup uid 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.

10 P Series

TECHNICAL SPECIFICATIONS

Product Type PC PG PJ/PK PR PW

Displacement in3/rev 0.37 0.62 0.73 0.97 1.33

[cc/rev] [6.1] [10.2] [12] [16] [21.8]

Input Speed

Maximum Unloaded rpm 3600 3600 3600 3600 3600 Minimum Loaded rpm 1800 1800 1800 1800 1800

System Operating Pressure

Continuous psi 750 1000 1000 1250 1250 [bar] [51] [70] [70] [86] [86] Intermittent psi 1750 2100 2100 2500 2500 [bar] [120] [145] [145] [172] [172]

Peak psi 2500 3500 3500 3750 3750

[bar] [172] [240] [240] [260] [260]

Pump Performance

@2400 rpm/1000 psi gpm [l/min] 3.6 [13.6] 6.1 [23.1] 7.1 [26.8] 9.6 [36.3] 13.1 [49.6] @3000 rpm/1000 psi gpm [l/min] 4.5 [17.0] 7.6 [28.8] 8.9 [33.6] 12 [45.4] 16.4 [62.1] @3600 rpm/1000 psi gpm [l/min] 5.4 [20.4] 9.2 [34.8] 10.8 [40.8] 14.4 [54.5] 19.6 [74.2]

Case Pressure

Maximum @ Cold Start psi [bar] 10 [0.7] 10 [0.7] 10 [0.7] 25 [1.7] 25 [1.7] Continuous - Max. psi [bar] 4 [0.3] 4 [0.3] 4 [0.3] 10 [0.7] 10 [0.7]

Inlet Vacuum

Maximum Continuous Inches Mercury 4 4 4 4 4

Charge Pump Displacement(s) in

[cc/rev] [2.1] [1.9/2.1] [3.2] [2.1/3.2] [2.1/3.2]

Auxiliary Pump Displacement in3/rev 0.19 0.19 0.19 0.19 0.19

[cc/rev] [3.2] [3.2] [3.2] [3.2] [3.2]

Auxiliary Pump Relief Setting

psi 650 650 650 650 650 [bar] [45] [45] [45] [45] [45]

Auxiliary Pump Performance

@3200 rpm, 500 psi, 70 SUS

[13 Cst] oil, & 180°F gpm 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0

[l/min] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6]

Control Torque Required to Stroke Pump

[Approximate - 20°External Stroke Angle]

lb-in / 1000 psi 75 85 85 95 105 [N-m / 70 bar] [8.5] [9.6] [9.6] [10.7] [11.9] lb-in / 500 psi 55 60 60 75 85 [N-m / 35 bar] [6.2] [6.8] [6.8] [8.5] [9.6]

Pump Oil Temperature

Maximum Intermittent (hottest point) °F 230 230 230 230 230 [°C] [110] [110] [110] [110] [110] Normal Operating Range °F -10 to 200 -10 to 200 -10 to 200 -10 to 200 -10 to 200 [°C] [-23 to 93] [-23 to 93] [-23 to 93] [-23 to 93] [-23 to 93]

3

/rev 0.13 0.11/0.13 0.19 0.13/0.19 0.13/0.19

Fluid Viscosity Limits @ 230°F [110°C]

Optimum SUS [cSt] 70 [13] 70 [13] 70 [13] 70 [13] 70 [13] Minimum SUS [cSt] 55 [9] 55 [9] 55 [9] 55 [9] 55 [9]

Weight of Unit

lbs [kg] 7 [3.2] 8 [3.6] 12.65 [5.7] 12 [5.4] 14 [6.3]

Inlet Filtration Requirement

Nominal micron 25 25 25 25 25

Table 1: P Series Pump Technical Specications

11P Series

PRODUCT IDENTIFICATION

HYDRO-GEAR

MADE IN U.S.A.

Model Number

PC-AGCC-MV1X-XXXX

4 244 P1 0192

Year Built

Date

(Julian - day of year)

Type of Product and Build Information

Serial Number

(unique number for that model - for that day)

The label in Figure 11 is located on the pump housing. It identies the model and conguration of the

pump.

Figure 11. P Series Pump Conguration Label

12 P Series

SECTION 2. SAFETY

This symbol points out important safety

instructions which, if not followed, could en-

danger 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.

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

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

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 oor should be clean and dry, and all extension

cords or similar trip hazards should be removed.

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 equip-

ment 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.

Never allow untrained or unauthorized personnel to service or repair the equipment.

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 ammable. Use only

approved cleaning materials: Do not use explosive

or ammable liquids to clean the equipment.

To avoid possible re, do not use cleaning solvents

in an area where a source of ignition may be present.

Discard used cleaning material in the appropriate containers.

13P Series

SECTION 3. TROUBLESHOOTING

In many cases, problems with the P Series Pump

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!

Possible Cause Corrective Action

VEHICLE DOES NOT DRIVE/TRACK STRAIGHT

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 adjust-

ments 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.

Vehicle tires improperly inated 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 lter partially blocked or Check all external lines and connections and lter

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 lter clogged Replace inlet lter

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

15P Series

P SERIES FLOW TEST KIT INSTRUCTIONS

(This Instruction Sheet supersedes all previous ow testing instructions)

BLN-51334 JULY 2010

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

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!

WARNING

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 ow is not necessary. The ow

meter may be connected in either direction into the forward and reverse high pressure system lines.

CAUTION: Ensure all ttings 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 ttings 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 ow meter restriction valve until the gauge reads 300 psi (21bar). Record the ow 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 ow

reading on the Bi-Directional Flow Meter.

10. The acceptable gpm “ow 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 efciently 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 7 gpm (26 l/min) (1st reading) 1100 psi (76 bar) reading -3 gpm (11 l/min) (2nd reading) 4 gpm (15 l/min) (the difference)

Subtract the 1st reading from the 2nd. (In this example, 4 gpm difference would indicate further pump examination).

17P Series

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 uid 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 ttings. An air leak may be difcult to

detect on the “suction side” or inlet line to the pump. Refer to Purging Procedures page 18.

5. Insure correct inlet lter(s) has been installed

in accordance with the vehicle manufacturer recommendations.

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.

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 ns and debris.

18 P Series

FLUIDS

The uids 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

ing temperature and an API classication of SJ/CD

is allowed. Refer to the vehicle manufacturer for recommended oil.

°

F (110° C) maximum operat-

FLUID VOLUME AND LEVEL

Certain situations may require additional uid to

be added or even replaced. Refer to the vehicle

manufacturer’s recommendations for the proper ll

location and level. After maintenance or oil change,

follow purging procedures below and check the uid level once the unit has been operated for ap-

proximately 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 uids.

FILTERS

An inlet lter is required to insure that only clean uid

enters the system. Refer to the vehicle manufacture

for approved lter replacement.

PURGING PROCEDURES

Due to the effects air has on efciency 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 inefciency 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. La ck of powe r or dr i ve af ter short-ter m

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 lu-

bricate 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, ll to the vehicle manufacturer’s specications.

The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.

19P Series

RETURN TO NEUTRAL SETTING

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, 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. Conrm 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.

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.

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

Figure 17. P Series Pump RTN Adjustment

Speed & Direction

Control Arm

20 P Series

REPAIR - PC SERIES PUMP

Repair - PC Series Pump ..................................................................................................... 21-36

How to Use This Manual..............................................................................................................21

General Instructions ....................................................................................................................21

T ools and Torques .......................................................................................................................22

Return to Neutral Linkage ............................................................................................................23

St andard Control Arm Linkage.....................................................................................................24

Fan Assembly..............................................................................................................................24

Input Shaft Seal ...........................................................................................................................25

Trunnion Arm Seal.......................................................................................................................25

Shock V alves...............................................................................................................................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.

GENERAL INSTRUCTIONS

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.

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.

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.

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).

21PC Series

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

TOOLS AND TORQUES

Table 1. Required T ools

Item # and/or Description

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 V alve 42A, 42B, Shock V alves/Check Plugs 44, System Charge Relief Kit (Aux Chg) 45, Aux Relief V alve 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

T orque

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) 1 10-130 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)

T able 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. Prior to disassembly , note the position of the scissor

arm brackets and the tab on the outer control arm bracket.

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.

1. Loosen (but do not remove) the nut (106).

2. T o 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), 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.

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

2. Inspect bushing (101) and all other linkage parts for damage, corrosion or wear.

Assembly

1. Install the inner return 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, washer (105) and bushing (101).

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

110

Figure 1. Return to Neutral Assembly

105

101

104

106

102

23PC Series

REMOV AL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM

REMOVAL, INSPECTION AND/OR REPLACEMENT OF F AN ASSEMBLY

Refer to Figure 2.

Disassembly

1. Remove the nut (106), washer (104) and bushing (101).

2. Remove the outer control arm bracket.

3. Remove bolt (103), washer (104) and the inner control arm bracket.

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

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 .

Refer to Figure 3.

Disassembly

1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs.

2. Remove the nut (106) and fan assembly (90).

3. Remove the bolts (10) and bracket (209).

Inspection

Inspect the fan shroud (210), fan assembly (90) and mounting bracket (209) for damage.

Assembly

1. T o 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.

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.

49

104

103

37

101

110

Figure 2. Standard Control Arm

104

106

3. 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

(2X) 10

90

106

210

Figure 3. Fan Assembly

24 PC Series

REMOV AL, INSPECTION AND/OR REPLACEMENT OF INPUT SHAFT SEAL

REMOV AL, INSPECTION AND/OR REPLACEMENT OF TRUNNION ARM SEAL

Refer to Figure 4.

Disassembly

1. Remove retaining ring (22) from housing.

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

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.

Refer to Figure 5.

Disassembly

1. Remove the RTN assembly or control arm.

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 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.

Figure 4. PC Pump Input Shaft Seal

6. Install the RTN assembly or control arm.

Figure 5. Trunnion Arm Seal

25PC Series

REMOV AL, INSPECTION AND/OR REPLACEMENT OF SHOCK V AL VES

REMOV AL, INSPECTION AND/OR REPLACEMENT OF THE BYP ASS

Refer to Figure 6. Perform disassembly, inspection and assembly on

shock valve one side at a time. Some units vary in “A” side to “B” side configuration.

Disassembly

1. Remove the shock valve (42) with an 11/16-inch wrench.

2. Remove the shock valve spring and the shock valve from the end cap.

Inspection

Inspect the shock valve (42) and mating seat in the end cap for damage or foreign material.

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 (T orque Values).

Refer to Figure 7.

Disassembly

1. Loosen the bypass valve (15) using a 7/16-inch wrench.

2. Remove the bypass (15) from the end cap.

Inspection

1. Inspect the bypass O-rings and mating seats in the end cap for damage or foreign material.

2. If damaged or worn, replace bypass (15).

Assembly

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 (T orque Values).

3. Repeat disassembly, inspection and assembly for the opposite port.

Figure 6. PC Pump Shock Valves

Figure 7. PC Pump Bypass

26 PC Series

REMOVAL, INSPECTION AND ASSEMBL Y OF THE STANDARD OR THRU SHAFT CHARGE PUMP

Refer to Figure 8.

NOTE: For thru shaft charge pump assembly, follow steps 1 thru 8. For standard charge pump, follow steps 3 thru 8.

Assembly

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, 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. 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.

1. Lubricate the new shaft seal with petroleum jelly.

2. Press the shaft seal into the charge cover. Be careful not to damage the shaft 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 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).

THRU SHAFT

6

(2X) 10

8

7

STANDARD

6

(2X) 10

Figure 8. PC Pump Standard or Thru Shaft Charge Pump

44

8

18

2

27PC Series

REMOV AL, INSPECTION AND/OR REPLACEMENT OF AUXILIAR Y PUMP (IF EQUIPPED)

3. Inspect the filter cover assembly threads and filter for wear, damage or foreign material.

Assembly

Refer to Figure 9.

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. 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. 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.

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.

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.

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.

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).

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. 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).

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.

2. Inspect all O-rings, gasket and mounting seats.

44A

6

8

44

67

54

66

(2X) 10

Figure 9. PC Series Auxiliary Pump

28 PC Series

45

164

7

8

(2X) 69

18

2

REMOV AL, INSPECTION AND

4

2

5

1

31

ASSEMBL Y OF THE END CAP

Refer to Figure 10.

Disassembly

3. Replace the housing gasket (5) with a new gasket before assembly .

Assembly

1. Install housing gasket (5) into housing gasket seat of housing (1).

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

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).

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). T ighten to the correct torque value. See Table 2, page 22 (Torque Values)

4. Install the charge pump. (See page 27).

Figure 10. PC Pump End Cap

29PC Series

REMOV AL, INSPECTION AND ASSEMBL Y OF THE CYLINDER BLOCK

Refer to Figure 1 1.

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.

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).

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

1. Apply a thin layer of clean oil to the pistons and springs.

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 inst alled, cut the rubber band and remove it from the housing.

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).

Figure 11. PC Pump Cylinder Block Assembly

30 PC Series

REMOV AL, INSPECTION AND ASSEMBL Y OF BLOCK SPRING AND THRUST BEARING

REMOV AL, INSPECTION AND ASSEMBL Y OF SW ASHPLA TE AND CRADLE BEARINGS

Refer to Figure 12.

Disassembly

1. Remove the block spring (29).

2. Remove the thrust bearing and races (34).

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).

Refer to Figure 13.

Disassembly

Remove the swashplate (32).

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 .

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.

2. Install block spring (29).

Figure 12. PC Pump Block Spring and

Thrust Bearing

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 13. PC Pump Swashplate and

Cradle Bearings

31PC Series

REMOV AL, INSPECTION AND ASSEMBL Y OF INPUT SHAFT

Refer to Figure 14.

Disassembly

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

Assembly

NOTE: If trunnion arm is to be removed, do not assemble input shaft until the trunnion arm is installed.

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 (23) onto the shaft (18).

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.

NOTE: Upon removal, all seals, O-rings and gaskets should be replaced.

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 shaf t 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).

Figure 14. PC Pump Input Shaft

32 PC Series

REMOVAL, INSPECTION AND INST ALLA TION OF TRUNNION ARM

Refer to Figure 15.

Assembly

1. Install the trunnion arm (37) into the housing (1) bore. Rotate the trunnion arm to verify free movement.

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

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.

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.

2. Install a new seal and seal retainer (49).

3. Install slot guide (38).

4. T o 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

37

Figure 15. PC Pump Trunnion Arm

49

33PC Series

34 PC Series

Figure 16. PC Pump

BOXES INDICA TE ITEMS INCLUDED IN KITS.

Kit Number

ITEM LIST - PC SERIES

Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.

No. Description

1 Housing Kit 2 End Cap 4 Screw, Hex Flange, M8 x 1.25 5 Housing O-Ring 6 Charge Pump Kit (Std. Charge)

Charge Pump Kit (St d. Charge) Thru

Shaft 7 STD Gerotor Assy (0.11 cu in./rev) 8 O-Ring 10 Cap Screw, Hex, 5/16 - 18 x 1.0 15 Bypass Valve Kit (No Bleed Orifice) 18 Pump Shaft Kit (1/2 in. Keyed w/Std.

Charge)

Pump Shaft Kit (1/2 in. Keyed, Thru

Shaft w St d. Charge

Pump Shaft Kit (9 tooth w/S td. Charge) 19 Ball Bearing, 17 x 40 x 12 mm 20 Lip Seal, 17 x 40 x 7 PTC 21 S p acer 22 Retaining Ring 23 Retaining Ring 25 Cylinder Block Kit 29 Block S pring 32 Swashplate 34 Ball Thrust Bearing 37 Trunnion Arm, Tapered Square

Trunnion

Arm, Double D 38 Slot Guide 42 Shock V alve 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

No. Description

44 Charge Relief Valve Kit (1/4 in. Plastic

Ball and 50654 Spring) 45 Auxiliary Relief Valve Kit 49 Trunnion Seal/Retainer Kit 54 Filter Kit 55 Plate, Adapter (Gear AA) 56 Plug, 5/16 - 24 66 Plug 67 Filter Cover 69 Pin, S traight Headless 80 Pin, S traight Headless 90 Fan Kit 100 Overhaul Seal Kit 101 Spacer , Return 102 Spring, Extension 103 Screw, 5/16 x 0.875 in. (PATCH) 104 Washer, 0.34 x 0.88 x 0.06 in. 105 Washer, Nylon 106 Nut, Hex Lock, 5/16 - 24 UNF 1 10 Return-to-Neutral Kit, Std.

Return-to-Neutral Kit, CW Scissor

Return-to-Neutral Kit, CCC Scissor

Return-to-Neutral Kit, 209 Shroud Bracket 210 Shroud

35PC Series

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.

GENERAL INSTRUCTIONS

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.

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.

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.

Parts requiring replacement must be replaced from

the appropriate kits identied in the Items Listing,

found at the end of this manual. Use only original Hydro-Gear replacement parts found listed in BLN51427 (CD).

37PG / PE Series

TOOLS AND TORQUES

Miscellaneous

P Series Service & Repair Manual

Torque Wrench

Scribe, Paint Pen, or Marker

Seal Hook with a Magnet

Flat Blade Screwdriver

Pliers

Internal Snap Ring

Allen Wrenches

5mm

3/16 inch

1/4 inch

3/8-Inch Drive Ratchet and Sockets

1/2-inch Socket

9/16-inch Socket

5/8-inch Socket

10-mm Socket

Combination Wrenches

1/2 inch

9/16 inch

5/8 inch

7/8 inch

10 mm

Table 1. Required Tools

Item # and/or Description

Case Drain (tting torque) System Port (tting torque) Inlet (tting 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

Table 2. PG / PE Pump Torque Values

Torque

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)

38 PG / PE Series

PG AND PE SERIES PUMP REPAIR

104

107

REMOVAL, INSPECTION AND/OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY

Refer to Figure 1.

Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control arm bracket.

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.

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).

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

2. Inspect scissor arm (99) and all other linkage

parts for damage, corrosion or wear.

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).

After serial # 8001PXXXXX

Figure 1. PG / PE Pump Return to Neutral

Prior to serial # 8001PXXXXX

39PG / PE Series

REMOVAL, INSPECTION AND/OR

107

104

REPLACEMENT OF CONTROL ARM

Refer to Figure 2.

REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY

Refer to Figure 3.

Disassembly

1. Remove the bolt (106), washer (104) and bushing (101).

2. Remove the outer control arm bracket.

3. Remove bolt (103), washer (104) and the inner control arm bracket.

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

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

Disassembly

1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs.

2. Remove the nut (106) and fan assembly (90).

3. Remove the bolts (10) and bracket (209).

Inspection

Inspect the fan shroud (210), fan assembly (90) and

mounting bracket (209) for damage.

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

(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.

Disassembly

1. Remove retaining ring (22) from housing.

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.

22

20

21

Refer to Figure 5.

Disassembly

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.

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.

19

18

1

Figure 4. PG / PE Pump Input Shaft Seal

1

37

49

Figure 5. PG / PE Pump Trunnion Arm Seal

41PG / PE Series

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 conguration.

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

1. Inspect the poppets and mating seats in the end

cap (2) for damage or foreign material.

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 conguration.

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 (2).

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 38 for torque values.

3. Repeat disassembly, inspection and assembly for the opposite port side.

42A

(PORT “A”

SIDE)

2

42B

(PORT “B”

SIDE)

Figure 6. PG / PE Pump Check Valves

Inspection

1. Inspect the check relief or shock valve (42) and

mating seat in the end cap (2) 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 38.

3. Repeat disassembly, inspection and assembly for the opposite port side.

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

43PG / PE Series

REMOVAL, INSPECTION AND ASSEMBLY OF STANDARD OR THRU SHAFT CHARGE PUMP

Refer to Figure 9.

Disassembly

Assembly

NOTE: For the Thru Shaft charge pump follow steps 1-8. For the Standard charge pump follow steps 3-8.

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. 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 t over the inner

gerotor.

6. Insert the O-ring 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 ts 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.)

THRU SHAFT

6

(2X) 10

Figure 9. PG / PE Pump Standard or Thru Shaft Charge Pump

44 PG / PE Series

44

18

2

STANDARD

REMOVAL, INSPECTION AND/OR REPLACEMENT OF AUXILIARY PUMP (IF EQUIPPED)

3. Inspect the lter cover assembly threads and lter for wear, damage or foreign material.

Assembly

Refer to Figure 10.

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 (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. Remove the plug (66) from the filter cover (67).

5. Use a 7/8 inch wrench to remove the lter cover

assembly (67) from the auxiliary pump.

6. Remove the O-ring and lter (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.

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.

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.

4. Install the lter (54) and O-ring onto the lter cover assembly (67). Install the assembly (67) into the auxiliary pump and tighten. Install plug (66) into the lter 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).

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.

10

44

69

6

64

66

67

Figure 10. PG / PE Series Auxiliary Pump

75

54

64

7

59

45

56

64

44A

59

2

45PG / PE Series

REMOVAL, INSPECTION AND ASSEMBLY OF THE END CAP AND VALVE PLATE

Refer to Figure 11a and 11b.

NOTE: Grooving in the valve plate and or

end cap, made evident when the surface is

checked by dragging a ngernail across it,

would be cause for replacement of the valve plate.

Disassembly

1. Using a 10 mm wrench, loosen the end cap bolts (4) evenly.

2. Keeping the end cap (2) held in place, remove the four end cap bolts (4).

3. Slowly remove the end cap (2).

4. Remove the valve plate (31).

NOTE: Not applicable in PE-series pumps.

5. Remove housing alignment pins (3).

6. Remove housing gasket (5).

Inspection

1. Inspect the end cap body (2) 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 (31). The running surface may show evidence of minor abrasive rings, this is normal.

3. Inspect and replace alignment pins (3) if bent

or distorted.

4. Replace the housing gasket (5) with a new gasket before reassembly.

Assembly

1. Install housing gasket (5) into housing gasket

seat of housing (1).

2. Install alignment pins (3) into housing (1).

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.

NOTE: Not applicable in PE-series pumps.

4. Lubricate the end cap (2) face prior to installation in PE-series pumps.

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

1

31

5

2

4

Figure 11a. PG Pump End Cap

46 PG / PE Series

4

Figure 11b. PE Pump End Cap

2

5

1

REMOVAL, INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK

Refer to Figure 12.

Disassembly

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.

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

47PG / PE Series

REMOVAL, INSPECTION AND ASSEMBLY OF BLOCK SPRING, THRUST WASHER, AND THRUST BEARING

Refer to Figure 13.

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.

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).

REMOVAL, INSPECTION OF SWASHPLATE, INSPECTION OF CRADLE BEARINGS

Refer to Figure 14.

Disassembly

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 at

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

29

Figure 13. PG / PE Pump Block Spring and Thrust

Bearing

48 PG / PE Series

29

32

34

30

(Cradle bearings cannot be removed from housing as depicted)

Figure 14. PG / PE Pump Swashplate and

38

37

Cradle Bearings

1

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.

Disassembly

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.

Assembly

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 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.

18

22

20

21

23

19

1

Figure 15. PG / PE Pump Input Shaft

49PG / PE Series

REMOVAL AND INSPECTION 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).

1

38

Inspection

1. Inspect the trunnion arm (37) for wear or damage.

Replace the trunnion arm if necessary.

Assembly

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).

37

49

Figure 16. PG / PE Pump Trunnion Arm

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

51PG / PE Series

Kit Number

BOXES INDICATE ITEMS INCLUDED IN KITS.

Figure 17. PG / PE Pump

52 PG / PE Series

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

No. Description

34 Ball Thrust Bearing 35 Stud, Torque 37 Trunnion Arm Trunnion, RTN 38 Slot Guide

42 Check Valve Kit (blank Orice) Check Valve Kit (0.024” Orice) Check Valve Kit (0.031” Orice) Check Valve Kit (0.044” Orice)

System Check / Relief Kit

System Check Relief Kit (.031” Orice)

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

53PG / PE Series

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.

GENERAL INSTRUCTIONS

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.

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.

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.

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).

55PJ Series

TOOLS AND TORQUES

Miscellaneous

P Series Service & Repair Manual

Torque Wrench

Scribe, Paint Pen, or Marker

Seal Hook with a Magnet

Flat Blade Screwdriver

Pliers

Internal Snap Ring

Allen Wrenches

5mm

1/8 inch

3/16 inch

1/4 inch

3/8-Inch Drive Ratchet and Sockets

7/16-inch Socket

1/2-inch Socket

9/16-inch Socket

5/8-inch Socket

11/16-inch Socket

10-mm Socket

Combination Wrenches

7/16 inch

1/2 inch

9/16 inch

5/8 inch

11/16 inch

7/8 inch

Item # and/or Description

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

10 mm

Table 1. Required Tools

Torque

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.

Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control arm bracket.

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.

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).

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

2. Inspect scissor arm (99) and all other linkage parts for damage, corrosion or wear.

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 74.

4. Install the scissor arm(99).

5. Install washer(104) and bolt (106)/nut (107) to the correct torque value. See page 74.

5. Install the spring (102).

After serial # 8001PXXXXX

Figure 1. PJ Pump Return to Neutral

Prior to serial # 8001PXXXXX

104

107

57PJ Series

REMOVAL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM

REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY

Refer to Figure 2.

Disassembly

1. Remove the bolt (106)/nut (107), washer (104) and bushing (101).

2. Remove the outer control arm bracket.

3. Remove bolt (103), washer (104) and the inner control arm bracket.

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

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.

Refer to Figure 3.

Disassembly

1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs.

2. Remove the nut (106) and fan assembly (90).

3. Remove the bolts (10) and bracket (209).

Inspection

Inspect the fan shroud (210), fan assembly (90) and mounting bracket (209) for damage.

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

56.

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.

Prior to serial # 8001PXXXXX

104

107

After serial # 8001PXXXXX

Figure 2. PJ Pump Standard Control Arm

3. Install the nut (106) and tighten per table 2, page

56.

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

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.

Disassembly

1. Remove retaining ring (22) from housing.

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

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).

3. Slide spacer (21) and seal (20) over the input shaft so that lettering on the seal faces out.

Refer to Figure 5.

Disassembly

1. Remove the RTN assembly or control arm.

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 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).

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.

5. Install the retaining ring (22) into the housing bore groove.

22

20

21

Figure 4. PJ Pump Input Shaft Seal

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 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.

6. Install the RTN assembly or control arm.

49

Figure 5. PJ Pump Trunnion Arm Seal

59PJ Series

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

1. Remove the check valve (42) with an 1/4” allen wrench.

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.

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.

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.

2. Remove the check relief/shock valve spring and the check relief/shock valve from the end cap.

Inspection

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

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

61PJ Series

REMOVAL, INSPECTION AND ASSEMBLY OF STANDARD OR THRU SHAFT CHARGE PUMP

Refer to Figure 9.

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.

Assembly

NOTE: For the Thru Shaft charge pump follow steps 1-8. For the Standard charge pump follow steps 3-8.

1. Lubricate the new shaft seal with petroleum jelly.

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

THRU SHAFT

8

7

10

Figure 9. PJ Pump Standard or Thru Shaft Charge Pump

62 PJ Series

7

18

2

8

STANDARD

6

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.

Assembly

Refer to Figure 10.

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).

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 auxiliary pump.

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.

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.

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).

5. Install the gasket (75) onto 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).

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.

44

54

67

10

64

66

6

Figure 10. Auxiliary Pump

44A

8

69

45

2

7

8

75

63PJ Series

REMOVAL, INSPECTION AND ASSEMBLY OF THE END CAP

Refer to Figure 11.

Disassembly

3. Replace the housing gasket (5) with a new gasket before assembly.

Assembly

1. Install housing gasket (5) into gasket seat of housing (1).

1. Remove charge pump. (See page 62).

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

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).

2. Lubricate the cylinder block (25) to end cap (2) mating surface with clean oil prior to installation.

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).

4. Install the charge pump. (See page 62.)

4

25

4

64 PJ Series

2

5

Figure 11. PJ Pump End Cap

1

REMOVAL, INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK

Refer to Figure 12.

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.

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.

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

65PJ Series

REMOVAL, INSPECTION AND ASSEMBLY OF BLOCK SPRING AND THRUST BEARING

REMOVAL, INSPECTION AND ASSEMBLY OF SWASHPLATE AND CRADLE BEARINGS

Refer to Figure 13.

Disassembly

1. Remove the block spring (29).

2. Remove the block thrust washer (30) and thrust bearing (34).

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).

Refer to Figure 14.

Disassembly

1. Remove the swashplate (32).

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.

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.

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).

34

30

29

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

1

49

Figure 13. Pump Block Spring and Thrust Bearing

66 PJ Series

Figure 14. PJ Pump Swashplate and Cradle

Bearings

REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT

Refer to Figure 15.

Disassembly

Assembly

NOTE: If trunnion arm is to be removed, do not assemble input shaft until the trunnion arm is installed.

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.

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.

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. 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).

Light tapping with a rubber mallet may

NOTE: Upon removal, all seals, O-rings and gaskets should be replaced.

1

Figure 15. PJ Pump Input Shaft

22

20

21

19

18

67PJ Series

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.

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

2. Check for excessive play between trunnion arm (37) and housing (1). Replace housing if necessary.

37

1

49

Figure 16. PJ Pump Trunnion Arm

68 PJ Series

69PJ Series

Kit Number

BOXES INDICATE ITEMS INCLUDED IN KITS.

Figure 17. PJ Pump

70 PJ Series

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

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 55 Plate, Adapter (Gear A) 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) 80 Pin, Straight Headless 85 R-Ring - 144 90 Hub / 6” Fan Kit

Hub / 7” CCW Fan Kit

Hub / 7” CW Fan Kit

Hug / 7” Fan Kit 98 Return Arm 99 Inner Scissor Arm 100 Seal Kit 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 Lock 5/16 - 24 UNF 110 Kit, RTN, STD

Kit, RTN, CW

Kit, RTN, CCW 209 Shroud Bracket 210 Shroud

71PJ Series

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.

GENERAL INSTRUCTIONS

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.

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.

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.

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).

73PK Series

TOOLS AND TORQUES

Miscellaneous

P Series Service & Repair Manual

Torque Wrench

Scribe, Paint Pen, or Marker

Seal Hook with a Magnet

Flat Blade Screwdriver

Pliers

Internal Snap Ring

Allen Wrenches

5mm

1/8 inch

3/16 inch

1/4 inch

3/8-Inch Drive Ratchet and Sockets

7/16-inch Socket

1/2-inch Socket

9/16-inch Socket

5/8-inch Socket

11/16-inch Socket

10-mm Socket

Combination Wrenches

7/16 inch

1/2 inch

9/16 inch

5/8 inch

11/16 inch

7/8 inch

Item # and/or Description

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

10 mm

Table 1. Required Tools

Torque

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.

Prior to disassembly, note the position of the scissor arm brackets and the tab on the outer control arm bracket.

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.

1. Loosen (but do not remove) the bolt (106).

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).

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

2. Inspect scissor arm (99) and all other linkage parts for damage, corrosion or wear.

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 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

75PK Series

REMOVAL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM

REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY

Refer to Figure 2.

Disassembly

1. Remove the bolt (106), washer (104) and bushing (101).

2. Remove the outer control arm bracket.

3. Remove bolt (103), washer (104) and the inner control arm bracket.

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (37) and trunnion arm seal (49).

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.

Refer to Figure 3.

Disassembly

1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs.

2. Remove the nut (106) and fan assembly (90).

3. Remove the bolts (10) and bracket (209).

Inspection

Inspect the fan shroud (210), fan assembly (90) and mounting bracket (209) for damage.

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

74.

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.

Figure 2. PK Pump Standard Control Arm

3. Install the nut (106) and tighten per table 2, page

74.

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

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.

Disassembly

1. Remove retaining ring (22) from housing.

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

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).

3. Slide spacer (21) and seal (20) over the input shaft so that lettering on the seal faces out.

Refer to Figure 5.

Disassembly

1. Remove the RTN assembly or control arm.

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 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).

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.

5. Install the retaining ring (22) into the housing bore groove.

22

20

21

Figure 4. PK Pump Input Shaft Seal

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 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.

6. Install the RTN assembly or control arm.

49

Figure 5. PK Pump Trunnion Arm Seal

77PK Series

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

1. Remove the check valve (42) with an 1/4” allen wrench.

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.

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.

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.

2. Remove the check relief/shock valve spring and the check relief/shock valve from the end cap.

Inspection

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

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

79PK Series

REMOVAL, INSPECTION AND ASSEMBLY OF STANDARD OR THRU SHAFT CHARGE PUMP

Refer to Figure 9.

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.

Assembly

NOTE: For the Thru Shaft charge pump follow steps 1-8. For the Standard charge pump follow steps 3-8.

1. Lubricate the new shaft seal with petroleum jelly.

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

THRU SHAFT

8

7

10

Figure 9. PK Pump Standard or Thru Shaft Charge Pump

80 PK Series

7

18

2

8

STANDARD

6

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.

Assembly

Refer to Figure 10.

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).

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 auxiliary pump.

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.

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.

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).

5. Install the gasket (75) onto 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).

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.

44

54

67

10

64

66

6

Figure 10. Auxiliary Pump

44A

8

69

45

2

7

8

75

81PK Series

REMOVAL, INSPECTION AND ASSEMBLY OF THE END CAP

Refer to Figure 11.

Disassembly

3. Replace the housing gasket (5) with a new gasket before assembly.

Assembly

1. Install housing gasket (5) into gasket seat of housing (1).

1. Remove charge pump. (See page 62).

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

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).

2. Lubricate the cylinder block (25) to end cap (2) mating surface with clean oil prior to installation.

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).

4. Install the charge pump. (See page 80.)

4

25

4

82 PK Series

2

5

Figure 11. PK Pump End Cap

1

REMOVAL, INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK

Refer to Figure 12.

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.

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.

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

83PK Series

REMOVAL, INSPECTION AND ASSEMBLY OF BLOCK SPRING AND THRUST BEARING

REMOVAL, INSPECTION AND ASSEMBLY OF SWASHPLATE AND CRADLE BEARINGS

Refer to Figure 13.

Disassembly

1. Remove the block spring (29).

2. Remove the block thrust washer (30) and thrust bearing (34).

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).

Refer to Figure 14.

Disassembly

1. Remove the swashplate (32).

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.

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

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).

34

30

29

Figure 13. Pump Block Spring and Thrust Bearing

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

1

49

Figure 14. PK Pump Swashplate and Cradle

Bearings

84 PK Series

REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT

Refer to Figure 15.

Disassembly

Assembly

NOTE: If trunnion arm is to be removed, do not assemble input shaft until the trunnion arm is installed.

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.

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.

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. 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).

Light tapping with a rubber mallet may

NOTE: Upon removal, all seals, O-rings and gaskets should be replaced.

1

Figure 15. PK Pump Input Shaft

22

20

21

19

18

85PK Series

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.

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

2. Check for excessive play between trunnion arm (37) and housing (1). Replace housing if necessary.

37

1

49

Figure 16. PK Pump Trunnion Arm

86 PK Series

87PK Series

Kit Number

BOXES INDICATE ITEMS INCLUDED IN KITS.

Figure 17. PK Pump

88 PK Series

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

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 55 Plate, Adapter (Gear A) 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) 80 Pin, Straight Headless 85 R-Ring - 144 90 Hub / 6” Fan Kit

Hub / 7” CCW Fan Kit

Hub / 7” CW Fan Kit

Hug / 7” Fan Kit 98 Return Arm 99 Scissor Arm 100 Seal Kit 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 110 Kit, RTN, STD

Kit, RTN, CW

Kit, RTN, CCW 209 Shroud Bracket 210 Shroud

89PK Series

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.

GENERAL INSTRUCTIONS

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.

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.

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.

Parts requiring replacement must be replaced from

the appropriate kits identied in the Items Listing,

found at the end of this manual. Use only original Hydro-Gear replacement parts found listed in BLN51427 (CD).

91PR Series

TOOLS AND TORQUES

Miscellaneous

P Series Service & Repair Manual

Torque Wrench

Scribe, Paint Pen, or Marker

Seal Hook with a Magnet

Flat Blade Screwdriver

Pliers

Internal Snap Ring

Allen Wrenches

5mm

3/16 inch

1/4 inch

3/8-Inch Drive Ratchet and Sockets

1/2-inch Socket

9/16-inch Socket

5/8-inch Socket

10-mm Socket

Combination Wrenches

1/2 inch

9/16 inch

5/8 inch

7/8 inch

10 mm

Table 1. Required Tools

Item # and/or Description

Case Drain (tting torque) System Port (tting torque) Inlet (tting 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

Torque

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.

See Figure 1.

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.

1. Loosen (but do not remove) the bolt (102).

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 (108), bolt (102), washer (99) and outer scissor arm bracket (103).

4. Remove bushing (106), washers (109), and the inner scissor arm bracket (104).

5. Remove the outer control arm bracket (101), bolt (107), washer (99), and inner control arm bracket (105).

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (13) and trunnion arm seal (12).

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),

washer (109) and bushing (106).

3. Install the inner scissor control arm bracket

(104), washer (109), and outer scissor control arm bracket (103).

4. Install washer (99), and bolt (102). Tighten to

the correct torque value. See page 92

5. Install the spring (108).

105

12

13

99

107

110

Figure 1. PR Pump Return to Neutral

101

109

106

104

103

108

99

102

93PR Series

REMOVAL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM

REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY

Refer to Figure 2.

Disassembly

1. Remove the bolt (102), washer (99) and bushing (106).

2. Remove the outer control arm bracket (101).

3. Remove bolt (107), washer (99) and the inner control arm bracket (105).

Inspection

1. With the arm control linkage removed, inspect the trunnion arm (13) and trunnion arm seal (12).

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.

105

12

101

110

Refer to Figure 3.

Disassembly

1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs.

2. Remove the fan nut and fan assembly (90).

3. Remove the bolts (56) and bracket (209).

Inspection

Inspect the fan shroud (210), fan assembly (90) and

mounting bracket (209) for damage.

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.

209

106

13

99

107

Figure 2. PR Pump Standard Control Arm

94 PR Series

99

102

1

56

90

210

Figure 3. PR Pump Fan Assembly

REMOVAL, INSPECTION AND/OR REPLACEMENT OF INPUT SHAFT SEAL

Refer to Figure 4.

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. With the lip seal (6) removed, inspect the spacer (4), shaft bearing (5) and housing (15) bore.

REMOVAL, INSPECTION AND/OR REPLACEMENT OF TRUNNION ARM (CONTROL ARM) SEAL

Refer to Figure 5.

Disassembly

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 (12) 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 (6) with petroleum jelly.

2. Wrap the input shaft (1) with plastic wrap to prevent damage to the inner surface of the lip seal (6).

3. Slide the seal (6) over shaft (1) so that lettering on the seal (6) 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.

5. Remove the plastic wrap.

6. Install the retaining ring (3) into the housing (15)

bore groove.

3

6

4

Assembly

1. Lubricate the new lip seal (12) with petroleum jelly.

2. Wrap the trunnion arm (13) with plastic wrap to prevent damage to the inner surface of the lip seal (12).

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 (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 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.

19

20

5

1

15

Figure 4. PR Pump Input Shaft Seal

15

13

12

Figure 5. PR Pump Trunnion Arm Seal

95PR Series

Cub Cadet P Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual