GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

9 5 6 4 7 8

Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston(1) & Replace
d D 0.039 0.067 piston or
cylinder bore(2)
(D-d) cylinder.

Play between
piston(1) & shoe caulking 0-0.1 0.3
section(3)
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 4.9 4.7

Free height of cylinder Replace

spring(4) cylinder
(L) 41.1 40.3
L spring.

Combined height of set

h H Replace
plate(5) & spherical
12.0 11.0 retainer or set
bushing(6)
plate.
(H-h)

Surface roughness for Surface roughness necessary

valve plate(sliding to be corrected 3z
face)(7,8), swash plate Lapping
(shoe plate area)(9), & Standard surface roughness 0.4z or lower
cylinder(2)(sliding face) (corrected value)

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2. MAIN CONTROL VALVE

Part name Inspection item Criteria & measure

Casing şExistence of scratch, rusting or şIn case of damage in following section,
corrosion. replace part.
- Sliding sections of casing fore and
spool, especially land sections
applied with holded pressure.
- Seal pocket section where spool is
inserted.
- Seal section of port where O-ring
contacts.
- Seal section of each relief valve for
main, travel, and port.
- Other damages that may damage
normal functions.

Spool şExistence of scratch, gnawing, şReplacement when its outside sliding

rusting or corrosion.
şO-ring seal sections at both ends.
şInsert spool in casing hole, rotate
and reciprocate it.
section has scratch(especially on
seals-contacting section).
şReplacement when its sliding section
has scratch.
şCorrection or replacement when
O-ring is damaged or when spool
does not move smoothly.

Poppet şDamage of poppet or spring şCorrection or replacement when

sealing is incomplete.
şInsert poppet into casing and function şNormal when it can function lightly
it. without being caught.

Around spring şRusting, corrosion, deformation or şReplacement for significant

breaking of spring, spring seat, plug damage.
or cover.

Around seal şExternal oil leakage. şCorrection or replacement.

for spool şRusting, corrosion or deformation of şCorrection or replacement.
seal plate.

Main relief valve, şExternal rusting or damage. şReplacement.

port relief valve & şContacting face of valve seat. şReplacement when damaged.
negative control şContacting face of poppet. şReplacement when damaged.
relief valve şAbnormal spring. şReplacement.
şO-rings, back up rings and seals. ş100$ replacement in general.

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3. SWING DEVICE
Part name Inspection item Remedy

Balance plate şWorn less than 0.03mm şLapping

şWorn more than 0.03mm şReplace
şSliding surface has a seizure(even şReplace
though small).

Shoe of piston şSliding surface has a damage. şLapping

assembly şSliding surface depression( ) şReplace parts or motor
dimension less than 0.45mm or has a
large damage.

Piston of piston şSliding surface has a seizure(even şReplace motor

assembly though small).

Piston hole of şSliding surface has a seizure. şReplace motor

cylinder assembly şSliding surface has a damage. şReplace motor

Taper roller bearing şIn case 3000hour operation. şReplace

Needle bearing şRolling surface has a damage. şReplace
Roller bearing

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4. TRAVEL DEVICE
Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.
1) SEALS
Once the seals (O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.
2) TABLE OF MAINTENANCE STANDARD
(1) Replace all parts having a seriously damaged appearance.
(2) Replace the part if any one of the states (symptoms) listed in the table below is observed.

Item Part name Situation Standard dimension Maximum allowable

value (Criteria)
Spindle kit
şSpindle assembly şSeriously damaged in
2 şşSpindle appearance.
8 şşCoupling gear şGalling or other forms of - -
17 şPin excessive wear are
observed.

Carrier assembly
3 Carrier şThe tooth surface of the
6 Cluster gear cluster gear(6) is
9 Shaft nonuniformly worn out - -
14 Thrust collar and damaged.
25 Needle bearing şThe cluster gear(6) does
34 Dowel pin not move smoothly.

4 Ring gear A şThe tooth surface is

nonuniformly worn out - -
and damaged.

5 Ring gear B şThe tooth surface is

nonuniformly worn out - -
and damaged.

7 Sun gear şThe tooth surface is

nonuniformly worn out
and damaged. - -
şThe spline section is
worn.

8 Coupling gear şExcessive wear or

pitching is observed on - -
the tooth surface.

19 Coupling şThe spline section is

- -
worn.

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Item Part name Situation Standard dimension Maximum allowable
value (Criteria)
20 Thrust bearing şWorn out. Axial clearance Clearance : 0.8mm
between coupling
gear (8) and cover
(13) : 0.3 to 0.6mm

22 Distance piece şThe sliding surface is

damaged.
- -
şThe sliding surface is
excessively worn out.

24 Ball bearing şDents are present.

şFlaking develops.
- -
şNonuniform wear is
present.

Rear flange kit

101 Rear flange şThe movable section Linear clearance : Linear clearance :
contacting the spool(123) 10 to 20 ҏ 20 ҏ
is damaged.
şThe clearance against the
spool (123) is too large.
şThe surface contacting
the valve (127) is
damaged.
şThe depth to the surface
contacting the valve (127)
is too large.
123 Spool şThe outer surface is
damaged.
şThe outer surface is
nonuniformly worn out.

102 Shaft şThe surface contacting

the oil seal(132) is worn
out. - -
şThe spline section is worn
out.

103 Swash plate şSeizure is observed. - -

104 Cylinder block şThe spline section is worn

out.
şThe bore inner surface is
worn out too much.
- -
şThe sliding surface that
contacts the timing
plate(109) is damaged or
nonuniformly worn out.

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Item Part name Situation Standard dimension Maximum allowable
value (Criteria)
Piston assembly
105 Piston şAn axial clearance is Clearance : 0.05mm Clearance : 0.15mm
106 Shoe present between the
piston(105) and the
shoe(106).
şThe shoe is excessively
worn out.
şThe shoe is nonuniformly
worn out.

107 Retainer plate şThe peripheral edge is

- -
nonuniformly worn out.

108 Thrust ball şThe spherical sliding

section that contacts the
retainer plate(107) is
nonuniformly worn out. - -
109 Timing plate şThe sliding surface has
the traces of seizure or
nonuniformly wear.

115 Friction plate şBoth edges are Braking torque Braking torque
nonuniformly worn out. 49.3kgfşm or more 49.3kgfşm or less
116 Mating plate şThe required torque
cannot be achieved.
şThe traces of seizure are
present.

118 Valve seat şThe seat surface is

- -
damaged.

119 Valve şThe outer surface is

damaged.
- -
şThe seat surface is
damaged.

Body kit
136 Body şThe sliding section that Linear clearance : Linear clearance :
contacts the spool(137) is 7 to 15 ҏ 20 ҏ
damaged.
şThe clearance against
the spool(137) is too
large.
137 Spool şThe outer surface is
damaged.
şThe outer surface is
nonuniformly worn out.

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Item Part name Situation Standard dimension Maximum allowable
value (Criteria)
149 Roller bearing şDents are present.
150 Ball bearing şFlaking develops.
- -
şNonuniform wear is
observed.

163 Valve şThe outer surface is

damaged.
- -
şThe seat surface is
damaged.

164 Stopper şThe seat surface is

- -
damaged.

142 Valve şThe outer surface is

damaged.
- -
şThe seat surface is
damaged.

172 Valve seat şThe seat surface is

- -
damaged.

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5. RCV LEVER

Maintenance Criteria Remark

check item
Leakage The valve is to be replaced when the leakage Conditions :
becomes more than 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000cc/m during Oil viscosity : 23cSt
operation.

Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10 ҏm, compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.

Push rod

‫ٻ‬7

1mm

This is to be replaced when the top end has

worn more than 1mm.

Play at operating The pin, shaft, and joint of the operating section When a play is due to looseness
section are to be replaced when their plays become of a tightened section, adjust it.
more than 2mm due to wears or so on.

Operation stability When abnormal noises, hunting, primary

pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6. Troubleshooting,
replace the related parts.

Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.

7 - 28
6. RCV PEDAL

Maintenance Criteria Remark

check item
Leakage The valve is to be replaced when the leakage Conditions :
effect to the system. For example, the primary Primary pressure : 30kgf/cm2
pressure drop. Oil viscosity : 23cSt

Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10ҏm, compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.

Push rod

‫ٻ‬7

1mm

This is to be replaced when th top end has

worn more than 1mm.

Play at operating The pin, shaft, and joint of the operating section When a play is due to looseness
section are to be replaced when their plays become of a tightened section, adjust it.
more than 2mm due to wears or so on.

Operation stability When abnormal noises, hunting, primary

pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6 troubleshooting, replace
the related parts.

Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.

7 - 29
7. TURNING JOINT

Part name Maintenance standards Remedy

Sliding surface Plating worn or peeled due to seizure or Replace

with sealing contamination.
sections.
Sliding surface şWorn abnormality or damaged more than 0.1mm Replace
Body, between body and
stem other than (0.0039in) in depth due to seizure contamination.
Stem
sealing section. şDamaged more than 0.1mm(0.0039in) in depth. Smooth with oilstone.
Sliding surface şWorn more than 0.5mm(0.02in) or abnormality. Replace
with thrust plate. şWorn less than 0.5mm(0.02in). Smooth
şDamage due to seizure or contamination Smooth
remediable within wear limit (0.5mm((0.02in).

Cover Sliding surface şWorn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate. şWorn less than 0.5mm (0.02in). Smooth
şDamage due to seizure or contamination
remediable within wear limit (0.5mm((0.02in).

şExtruded excessively from seal groove square Replace

ring.

- Extrusion
Square ring

şSlipper ring 1.5mm(0.059in) narrower than seal Replace

groove, or narrower than back ring.

Seal set -

1.5mm (max.)
(0.059in)

şWorn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) Replace

(0.059in)

7 - 30
8. CYLINDER

Part name Inspecting section Inspection item Remedy

Piston rod şNeck of rod pin şPresence of crack şReplace

şWeld on rod hub şPresence of crack şReplace
şStepped part to which şPresence of crack şReplace
piston is attached.
şThreads şPresence of crack şRecondition or replace
şPlated surface şPlating is not worn off to şReplace or replate
base metal.
şRust is not present on şReplace or replate
plating.
şScratches are not present. şRecondition, replate or
replace
şRod şWear of O.D. şRecondition, replate or
replace
şBushing at mounting part şWear of I.D. şReplace
Cylinder tube şWeld on bottom şPresence of crack şReplace
şWeld on head şPresence of crack şReplace
şWeld on hub şPresence of crack şReplace
şTube interior şPresence of faults şReplace if oil leak is seen
şBushing at mounting part şWear on inner surface şReplace
Gland şBushing şFlaw on inner surface şReplace if flaw is deeper
than coating

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