GROUP 3 PUMP DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

Escaping fluid under pressure can
13 4
penetrate the skin causing serious 1
5
injury. 2

(4) Loosen the drain plug under the hydraulic

tank and drain the oil from the hydraulic
tank.
 Hydraulic tank quantity : 180˶
(5) Remove socket bolts (13) and disconnect 12
3
pipe (1,2). 210N78MP01

(6) Disconnect pilot line hoses (4, 5, 6, 7, 8, 9,

10, 11).
(7) Remove socket bolts (12) and disconnect 6
8
pump suction pipe (3). 9
7
ö When pump suction pipe is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(8) Sling the pump assembly and remove the 10
pump mounting bolts. 11
 Weight : 170kg (370lb) 210N78MP02
ö Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.

8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace the return filter with a new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
Η Remove the air vent plug (2EA)
Θ Tighten plug lightly
Ι Start the engine, run at low idling, and
check oil come out from plug.
Κ Tighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.

8-8
2. MAIN PUMP (1/2)
1) STRUCTURE

536 490 793 548 901 732 807 412 080

406 703 532 531 789 953
806 534 214 535 410
408 954 492 885

X X

A A

543 545
888 406 469 725 981 409 316 735 541
251 157 211 728 141 467 983
212 156 152 153 151 410 709 724
726

828 123 724 469 129 826 271 491 314 490
728 491
171 490 124 04
127
SECTION X-X
824
113
192
709
827
774

111
261
825
126
191 122 823 752 124 886 312
828 887 751 490 128 726 313

SECTION A-A
210N72MP02

8-9
 04 Gear pump 271 Pump casing 724 O-ring
080 Proportional reducing 312 Valve cover 725 O-ring
valve assy 313 Valve plate (R) 726 O-ring
111 Drive shaft 314 Valve plate (L) 728 O-ring
113 Driven shaft 316 Cover 732 O-ring
122 Roller bearing 406 Hexagon socket bolt 735 O-ring
123 Roller bearing 408 Hexagon socket bolt 751 Packing
124 Needle bearing 409 Hexagon socket bolt 752 Seat packing
126 Bearing spacer 410 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 412 Hexagon socket bolt 789 Back up ring
128 Bearing spacer 467 Plug 793 Back up ring
129 Bearing spacer 469 Plug 806 Nut
141 Cylinder block 490 Plug 807 Nut
151 Piston 491 Plug 823 Snap ring
152 Shoe 492 Restrictor 824 Snap ring
153 Set plate 531 Tilting pin 825 Snap ring
156 Bushing 532 Servo piston 826 Snap ring
157 Cylinder spring 534 Stopper (L) 827 Snap ring
171 Front casing 535 Stopper (S) 828 Snap ring
191 Drive gear 536 Servo cover 885 Valve plate pin
192 Driven gear 541 Seat 886 Spring pin
211 Shoe plate 543 Stopper 887 Spring pin
212 Swash plate 545 Steel ball 888 Pin
214 Tilting bushing 548 Feed back pin 901 Eye bolt
251 Swash plate support 703 O-ring 953 Set screw
261 Front cover 709 O-ring 954 Set screw

8-10
 MAIN PUMP(2/2)
490

Psv a

490 724 407 467,725

P2 Pi
Psv a
A1

724

079 732 325 210N72MP03

079 Proportional reducing valve 467 Plug 725 O-ring

325 Valve casing 490 Plug 732 O-ring
407 Hexagon socket screw 724 O-ring

8-11
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.

Tool name & size Part name

Hexagon socket PT plug PO plug
B Servo piston
Allen wrench head cap screw (PT thread) (PF thread)
4 M 5 BP-1/16 - -
5 M 6 BP-1/ 8 - -
6 M 8 BP-1/ 4 PF-1/4 -
B 8 M10 BP-3/ 8 PF-3/8 -
10 M12 BP-1/2 PF-1/2 -
14 M16, M18 BP-3/4 PF-3/4 M24
17 M20, M22 BP-1 PF-1 -
19 M24, M27 - - -

Double ring spanner, Hexagon socket

- Hexagon head screw Hexagon hut head set screw
socket wrench,
double (Single) open end 19 M12 M12 -
spanner
24 M16 M16 -

B 27 M18 M18 -
30 M20 M20 -
36 - - -
46 M30 M30 -
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160, TSR200
Steel bar Steel bar of key material approx. 10Ý8Ý200
Torque wrench Capable of tightening with the specified torques
Seal tape For BP-1/4

8-12
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435)
M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
M22 64.0 462.9 0.67 17
PT plug (Material : S45C) PT 1/16 0.7 5.1 0.16 4
ö Wind a seal tape 1 1/2 to
PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PT 3/ 8 3.5 25.3 0.31 8
PT 1/ 2 5.0 36.2 0.39 10
PF plug (Material : S45C) PF 1/ 4 3.0 21.7 0.24 6
PF 1/ 2 10.0 72.3 0.39 10
PF 3/ 4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17

8-13
3) DISASSEMBLY
(1) Select place suitable to disassembling.
ö Select clean place.
ö Spread rubber sheet, cloth or so on
overhaul workbench top to prevent parts
from being damaged.
ö Fix pump casing (271) by using thread
2-M10Ý16 in disassembling.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove outlet port plug (469, lower part
of pump casing) and let the oil out of
pump casing.
ö In order to be let the oil out of pump
casing easily, remove oil filling port plug
(469, upper part of pump casing).

(4) Remove hexagon socket head cap screws

(412, 413) and remove regulators.
ö In order to avoid mixing up regulator of
drive shaft side with that of driven shaft
side, mark each of them.
Remove hexagon socket head cap screws
(435) and remove gear pump.
Remove hexagon socket head cap screws
(407) and remove proportional reducing
valve. 210N78MP29

(5) Loosen hexagon socket head cap screws

(410, 412) which tighten valve cover (312).
Loosen hexagon socket head cap screws
(6) (410, 411) which tighten valve cover (312).
Remove regulators, gear pump and
proportional reducing valve before starting
ö this work.

8-14
(7) Place pump horizontally on workbench
and separate pump casing (271) and
valve cover (312).
ö Remove valve cover carefully at this work
because it is heavy (about 29kgf).
ö There are two spring pins for fixing
position between pump casing and valve
cover. Since they have a tight fit, remove
valve cover upright with respect to drive
shaft (111) and driven shaft (113), while 210N78MP03
lightly tapping the valve cover with a
plastic hammer.
ö Take care not to damage fitting surfaces
between pump casing and valve cover.
Take care not to drop valve plates (313,
314), check valve subassemblies (541,
543, 545), O-rings (735) and seat packing
(752) in removing valve cover.

(8) If necessary, remove needle bearings (124)

from valve cover (312).
ö Do not remove needle bearings as far as
possible, except when it is considered to
be out of its life span.
ö Do not loosen hexagon nut (807) of the
valve cover. If loosened, flow setting will
be changed.

(9) Pull cylinders out of pump casing (271)

straightly over drive shaft (111) and driven
shaft (113). Pull out also pistons (151),
set plate (153), spherical bush (156) and
cylinder springs (157) simultaneously.
ö Take care not to damage sliding surfaces
of cylinder, spherical bush, shoes, swash
plate, and so on.

210N78MP04

8-15
(10) Remove shoe plate (211) and swash plate
(212) from pump casing (271).
ö Separate shoe plate from swash plate,
using a flat-blade screwdriver.
Them remove swash plate.

210N78MP05

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

stopper (S, 535), servo piston (532), tilting
pin (531), and servo cover (536) from
pump casing (271).
ö In removing tilting pin, use a protector to
prevent pin head from being damaged.
ö Since adhesive (No.1305N of Threebond
make) is applied to fitting areas of tilting
pin and servo piston, take care not to
damage servo piston.
ö Do not loosen hexagon nut (806) on servo
cover (536). If loosened, flow setting will
be changed.

(12) Remove snap ring (827) and front cover

(261) from front casing (171).
ö A groove is provided on the outer
circumference of front cover straight with
respect to drive shaft (111) by placing a
minus type screwdriver in the groove.
ö Since oil seal (774) is fitted on front cover
(261), take care not to damage it in
removing.
(13) Loosen hexagon socket head cap screws 210N78MP06

(408) which tighten front casing (171).

8-16
(14) Separate front casing (171) and pump
casing (271).
ö Take care of front casing not to fall
because it is heavy (about 23kgf).
ö There are two spring pins (887) for fixing
position between front casing and pump
casing. Tapping lightly with a plastic
hammer, remove front casing
perpendicular to drive shaft because they
are fitted firmly. When removing, take 210N78MP07
care not to damage oil seal sliding surface
of drive shaft.
ö Take care not to damage fitting surfaces
between front casing and pump casing.
ö There is a packing (751) between front
casing and pump casing. The packing is
made of synthetic resin and easy to break.
In case it is broken or scored, replace it
with a new one.

(15) Remove snap rings (824, 825), bearing

spacers (126, 127), drive gear (191) and
driven gear (192).

210N78MP24

(16) Remove snap ring (828) and take out

drive shaft (111) and driven shaft (113)
tapping lightly ends of them by plastic
hammer and so on.

210N78MP08

8-17
(17) If necessary, remove snap rings (823,
825, 826), bearing spacer (128, 129), and
roller bearing (122, 123) from drive shaft
(111) and driven shaft (113).
ö Do not remove roller bearing as far as
possible, except when it is considered to
be out of its life span. Use a specified jig
in removing because roller bearing is
shrinkage fitted to shaft.

(18) Loosen hexagon socket head cap screws

(406) which tighten swash plate supports
(251) and pump casing (271).
ö Adhesive (No.1305N of Threebond make)
is applied to hexagon socket head cap
screws (406).

(19) Remove swash plate supports (251) from

pump casing (271).

ö This is the end of disassembling

procedures.
210N78MP09

8-18
4) REASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
Η Do not fail to repair the parts damaged
during disassembling, and repair
replacement parts in advance.
Θ Clean each part fully with cleaning oil and
dry it with compressed air.
Ι Do not fail to apply clean working oil to
sliding surfaces, bearings, etc. before
assembling them.
Κ In principle, replace seal parts, such as
O-rings, oil seals, etc.
Λ Apply grease to O-rings, seat packing,
and check valves in assembling them
because they tend to come off.
Μ In case of parallel type pump, rotating
directions of drive shaft and driven shaft
are different. Take care not to mix up
parts of the drive shaft side with those of
the driven shaft side.
Ν For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with specified torques in this service
manual.

(2) Select place suitable to assembling.

ö Select clean place.
ö Spread rubber sheet, cloth or so on
overhaul workbench top to prevent parts
from being damaged.
ö Fix pump casing (271) by using thread
2-M10Ý16 in assembling.

8-19
(3) Fit swash plate support (251) to pump
casing (271) and fix them with hexagon
socket head cap screws (406).
ö There are O-rings (724) on the matching
surface in contact with pump casing (271).
ö Fix them with grease so they do not come
off.
ö Positioning pin (888) is placed on the
pump casing (271) side. Adjust it so it
enters the groove of swash plate support 210N78MP09
(251) and fix it.
ö Fit swash plate support (251) so it enters
straight, while tapping it lightly.
ö Apply adhesive (No.1305N of Threebond
make) to hexagon socket head cap
screws.

210N78MP12

(4) To pump casing (271), fit drive shaft (111)

set and driven shaft (113) set with roller
bearing (122, 123), bearing spacer (128,
129), and snap rings (823, 826). Then fix
them with snap rings (828).
ö Direct the sharp edge side of snap rings
(823, 826) to the outside.
ö Do not tap shafts with hammer or so on.
ö Assemble them into pump casing, tapping
outer race of bearing lightly with plastic
45078MP13
hammer. Fit them fully using steel bar or
so on.
ö When fitting snap rings (828), direct the
sharp edge side of snap ring to the outside.

(5) Fit drive gear (191), driven gear (192), and

bearing spacers (126, 127) to drive shaft
(111) and driven shaft (113). Then fix
them with snap rings (824, 825).
ö Confirm the attaching direction of drive
gear before fitting.
ö Direct the sharp edge of snap rings (824,
825) to the outside.

210N78MP24

8-20
(6) Fit front casing (171) to pump casing (271)
and fix them with hexagon socket head cap
screws (408).
ö Take care of front casing not to fall because it
is heavy (about 23kgf).
ö There are two spring pins (887) for fixing
position between front casing and pump
casing. Always fit spring pins (887) to the
pump casing side.
ö Fit front casing to pump casing perpendicular 210N78MP07
to drive shaft, while tapping it lightly because
spring pin (886) has a tight fit. When fitting,
take care not to damage oil seal sliding
surface of drive shaft.
ö Take care not to damage fitting surfaces of
front casing and pump casing.
ö There is a packing (751) between front casing
and pump casing. The packing is made of
synthetic resin and easy to break. In case it is
broken or scored, replace it with a new one.
ö Apply grease to seat packing (751) because it
210N78MP16
tends to come off.

(7) Fit front cover (261) to front casing (171)

and fix them with snap ring (827).
ö Apply grease lightly to oil seal in front
cover.
ö Assembling oil seal, take full care not to
damage it.
ö Direct the sharp edge of snap ring (827) to
the outside.

210N78MP06

(8) Place pump casing (271) horizontally. Fit

servo piston (532), tilting pin (531), stopper
(L, 534), and stopper (S, 535) to pump
casing. Then fit servo cover (536) to pump
casing and fix them with hexagon socket
head cap screws (406).
ö Fix pump casing by using thread 2-M10Ý16
in assembling.
ö In tightening servo piston and tilting pin, use
a protector to prevent tilting pin head and
feedback pin from being damaged. In
addition apply adhesive (No.1305N of
Threebond make) to their threaded sections.

8-21
(9) Fit tilting bush (214) of swash plate (212)
to tilting pin (531) and fit swash plate to
swash plate support (251) correctly.
ö Take care not to mix up parts of drive shaft
side with those of driven shaft side.
ö Even after fitting, swash plate (212) comes
off from swash plate support (251), in
some cases. They do not come off easily
if grease is applied to the sliding surfaces.
ö Confirm with fingers of both hands that 210N78MP17
swash plate can be moved smoothly.

(10) Assemble piston cylinder subassembly

[cylinder (141), piston subassembly (151,
152), set plate (153), spherical bush (156),
cylinder spring (157)]. Fit spline phases of
spherical bush and cylinder and insert piston
cylinder subassembly into pump casing with
respect to drive shaft (111) and driven shaft
ö (113).
Take care not to mix up parts of drive shaft
side with those of driven shaft side. 210N78MP25
ö Confirm that swash plate (212) is not off
from swash plate support (251) and from
tilting pin (531), before inserting them.

(11) Fit valve plates (313, 314) to valve cover,

entering valve plate pin (885) into pin hole.
ö Take care not to mistake suction/delivery
directions of valve plate.
ö Apply grease to matching surface in
contact with valve cover (312) because
valve plates (313, 314) tend to come off.

210N78MP18

(12) Insert check valve subassemblies (541,

543, 545) and needle bearings (124) to
valve cover (312).
ö Insert check valve subassemblies into
valve cover in correct order.
ö Since check valve subassembly tends to
come off, apply grease to matching part of
valve cover (312).

210N78MP26

8-22
(13) Fit O-ring (724, 725, 726) and seat
packing (752) to the matching surface of
pump casing (271) in contact with valve
cover (312).
ö Since O-rings and seat packing tend to
come off, apply grease to matching
surface.

210N78MP19

(14) Fit valve cover (312) to pump casing (271)

and tighten them with hexagon socket
head cap screws (410, 412).
ö Crane valve cover at this work because it
is heavy (about 29kgf).
ö Confirm that swash plate (212) is not off
from swash plate support (251) and tilting
pin (531) before fitting.
ö Needle bearings (124) are located on the
valve cover side place the valve cover with 210N78MP03
care.
ö When fitting, take care as valve plates
(313, 314) check valve subassemblies
(541, 543, 545), O-rings (735), and seat
packing (752) may come off in some
cases.
ö There are two spring pins (886) for fixing
position between pump casing and valve
cover. Since spring pin (886) has a tight
fit, fit valve cover upright to drive shaft
(111) and driven shaft (113), while tapping
210N78MP21
it with a plastic hammer.
ö Take care not to damage fitting surfaces
between valve cover and pump casing.

8-23
(15) Putting feedback pin (548) of tilting pin
(531) into feedback lever of regulator, fit
regulator and tighten hexagon socket
head cap screws (412, 413).
ö Since the regulators on the drive shaft
side and the driven shaft side are set at
different pressure and flow values, take
care not to mistake one for another.

210N78MP29

(16) Install gear pump (04) and proportional

reducing valve (080) and tighten them with
flange socket bolt (435) (for gear pump)
and hexagon socket head cap screws
(407) (for proportional reducing valve).
Since gear pump is an aluminum casing,
ö the tightening torque for the flange socket
bolts (435) differs from it for hexagon
socket head cap screw.
210N78MP28

8-24
5) REGULATOR (1/2)

412 897 876 874

A 755
612 B
858 A
KR3G-9S09
614 P2
615
Pf

613 Pm
611
Pi
A B 875

Hydraulic circuit
B

647 Pi

723 438
642
801 924

C
801

648 730 643 708 644 646 645 728

210N7A2RG01
SECTION B-B

735 413 496 438 Pm 413

Port Port name port size

Pi Pilot port PF 1/4 - 15

438
Pm Qmax cut port PF 1/4 - 15

656

722 724 725 436

VIEW C

8-25
 REGULATOR (2/2)

734 653 654 836 651 652 601 624 629 630
655
641
814
628
733
732 802

898
627
631
753

756

622 621 623 625 626 887 763

SECTION A-A
210N7A2RG02A

412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Adjust screw (QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat (Q) 735 O-ring
601 Casing 645 Adjust stem (Q) 753 O-ring
611 Feed back lever 646 Pilot spring 755 O-ring
612 Lever (1) 647 Stopper 756 O-ring
613 Lever (2) 648 Piston (QMC) 763 O-ring
614 Center plug 651 Sleeve 801 Nut
615 Adjust plug 652 Spool 802 Nut
621 Compensator piston 653 Spring seat 814 Snap ring
622 Piston case 654 Return spring 836 Snap ring
623 Compensator rod 655 Set spring 858 Snap ring
624 Spring seat (C) 656 Block cover 874 Pin
625 Outer spring 708 O-ring 875 Pin
626 Inner spring 722 O-ring 876 Pin
627 Adjust stem (C) 723 O-ring 887 Pin
628 Adjust screw (C) 724 O-ring 897 Pin
629 Cover (C) 725 O-ring 898 Pin
630 Lock nut 728 O-ring 924 Set screw

8-26
 6) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the regulators are shown in the follow list.

Tool name & size Part name

Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew

Allen wrench 4 M 5 BP-1/16 - M 8

B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double(Single) Hexagon head VP plug
open end spanner - Hexagon nut
bolt (PF thread)
B

36 - - VP-3/4
Adjustable angle wrench Medium size, 1set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-150
Steel bar ͚4Ý100mm
Torque wrench Capable of tightening with the specified torques
Pincers -
Hexagon socket head cap screw M4Ý50mm

8-27
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug (Material : S45C) PT1/16 0.7 5.1 0.16 4
öWind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug (Material : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17

8-28
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembling and
assembling are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembling
is necessary for an unavoidable reason,
read through this manual to the end before
starting disassembling.
(1) Select a place for disassembling.
ö Select a clean place.
ö Spread rubber sheet, cloth, or so on top of
work-bench to prevent parts from being
damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
ö Since the regulators on the drive shaft
side and the driven shaft side are set at
different pressure and flow values, mark
each of them so as not to mix up one of
drive shaft side with another.

(3) Remove hexagon socket head cap screw

(412, 413) and remove regulator main
body from pump main body.
ö Take care not to lose O-ring.

REG01 (210-7)

(4) Remove hexagon socket head screw

(438) and remove cover (C,629)
ö Cover (C) is fitted with adjusting screw
(C,QI) (628), adjusting ring (C, 627), lock
nut (630), hexagon nut (802) and
adjusting screw (924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
REG02 (210-7)

8-29
(5) After removing cover (C, 629) subassembly,
take out outer spring (625), inner spring
(626) and spring seat (C, 624) from
compensating section.
Then draw out adjusting ring (Q, 645),
pilot spring (646) and spring seat (644)
from pilot section.
ö Adjusting ring (Q,645) can easily be
drawn out with M4 bolt.
REG03 (210-7)

(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover (641).
After removing pilot cover, take out set
spring (655) from pilot section.

REG04 (210-7)

(7) Remove snap ring (814) and take out

spring seat (653), return spring (654) and
sleeve (651).
ö Sleeve (651) is fitted with snap ring (836).
ö When removing snap ring (814), return
spring (654) may pop out.
Take care not to lose it.

REG05 (210-7)

(8) Remove snap ring (858) and take out

fulcrum plug (614) and adjusting plug
(615).
ö Fulcrum plug (614) and adjusting plug
(615) can easily be taken out with M6 bolt.

REG06 (210-7)

8-30
 REG07 (210-7)

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

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

REG08 (210-7)

(10) Draw out pin (874) and remove feedback

lever (611).
ö Push out pin (874, 4mm in dia.) from
above with slender steel bar so that it may
not interfere with lever (1, 612).

REG09 (210-7)

REG10 (210-7)

8-31
(11) Remove lever (1, 612). Do not draw out
pin (875).
(12) Draw out pilot piston (643) and spool
(652).
(13) Draw out piston case (622), compensating
piston (621) and compensating rod (623).
ö Piston case (622) can be taken out by
pushing compensating rod (623) at
opposite side of piston case.

This completes disassembling.

8-32
4) ASSEMBLY
(1) For assembling, reverse disassembling
procedures, but pay attention to the
following.
Η Always repair parts that were scored at
disassembling.
Get replacement parts ready beforehand.
Θ Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
Ι Always tighten bolts, plugs, etc. to their
specified torques.
Κ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembling.
Λ Replace seals such as O-ring with new
ones as a rule.

(2) Put compensating rod (623) into

compensating hole of casing (601).
(3) Put pin force-fitted in lever (1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.

(4) Fit spool (652) and sleeve (651) into hole

in spool of casing.
ö Confirm that spool and sleeve slide
smoothly in casing without binding.
ö Pay attention to orientation of spool.

Spool

Feedback lever
8-27 (210-7)

8-33
(5) Fit feedback lever (611), matching its pin
hole with pin hole in spool.
Then insert pin (874).
ö Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
ö Take care not to mistake direction of (Fulcrum plug of
adjusting plug side)
feedback lever.

8-28 (210-7)

(6) Put pilot piston (643) into pilot hole of

casing.
ö Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever (2, 613) into
groove of pilot piston.
Then fix lever (2).

REG11 (210-7)

(8) Fit fulcrum plug (614) so that pin force-

fitted in fulcrum plug (614) can be put into
pin hole of lever (2).
Then fix snap ring (858).
(9) Insert adjusting plug (615) and fit snap
ring.
ö Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
REG12 (210-7)
free from binding.

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

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

REG13 (210-7)

8-34
(11) Fit set spring (655) to spool hole and put
compensating piston (621) and piston
case (622) into compensating hole.
Fit pilot cover (641) and tighten it with
hexagonal socket head screws (436,
438).

REG14 (210-7)

(12) Put spring seat (644), pilot spring (646)

and adjusting ring (Q, 645) into pilot hole.
Then fix spring seat (624), inner spring
(626) and outer spring (625) into
compensating hole.
ö When fitting spring seat, take care not to
mistake direction of spring seat.

REG15 (210-7)

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

screws (628), adjusting ring (C, 627), lock
nut (630), hexagon nut (802) and
adjusting screw (924).
Then tighten them with hexagonal socket
head screws (438).

REG16 (210-7)
This completes assembling.

8-35