GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

9 6 5 4 7 8

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

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

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

Combined height of set

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

Surface roughness for Surface roughness

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

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2. MAIN CONTROL VALVE

Part name Inspection item Criteria & measure

Casing ş Existence of scratch, rusting or corrosion ş In case of damage in following section,

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 ş Existence of scratch, gnawing, rusting or ş Replacement when its outside sliding
corrosion. section has scratch(Especially on seals-
contacting section).
ş O-ring seal sections at both ends. ş Replacement when its sliding section has
scratch.
ş Insert spool in casing hole, rotate and ş Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.

Poppet ş Damage of poppet or spring. ş Correction or replacement when sealing

is incomplete.
ş Insert poppet into casing and function it. ş Normal when it can function lightly
without being caught.

Around spring ş Rusting, corrosion, deformation or breaking ş Replacement for significant damage.
of spring, spring seat, plug or cover.

Around seal for spool ş External oil leakage ş Correction or replacement

ş Rusting, corrosion or deformation of seal ş Correction or replacement
plate

Main relief valve, port ş External rusting or damage ş Replacement

relief valve & negative ş
Contacting face of valve seat
control relief valve
ş Contacting face of poppet
ş Abnormal spring
ş O-rings, back up rings and seals
ş Replacement when damaged
ş Replacement when damaged
ş Replacement
ş 100$ replacement in general

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3. SWING DEVICE

Part name Inspection item Criteria & measure

Balance plate ş Worn less than 0.03mm ş Lapping

ş Worn more than 0.03mm ş Replace
ş Sliding surface has a seizure(Even ş Replace
though small).

Shoe of piston ş Sliding surface has a damage. ş Lapping

assembly ş Sliding surface depression( ş Replace parts or motor
)
dimension less than 0.45mm or has a
large damage.

Piston of piston ş Sliding surface has a seizure(Even ş Replace motor

assembly though small).

Piston hole of ş Sliding surface has a seizure. ş Replace motor

cylinder assembly ş Sliding surface has a damage. ş Replace motor

Taper roller bearing ş In case 3000hour operation. ş Replace

Needle bearing ş Rolling surface has a damage. ş Replace
Roller bearing

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4. RCV LEVER

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

Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10ҏm, compared with the non-sliding estimated to be nearly equal to the
surface. 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 are to When a play is due to looseness of
section be replaced when their plays become more than 2mm a tightened section, adjust it.
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.

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5. ACCELERATOR PEDAL
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect to Conditions :
the system. For example, the primary pressure drop. Primary pressure : 30kgf/cm 2
Oil viscosity : 23cSt

Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10ҏm, compared with the non-sliding estimated to be nearly equal to the
surface. 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 are to When a play is due to looseness of
section be replaced when their plays become more than 2mm a tightened section, adjust it.
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.

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6. TURNING JOINT

Part name Maintenance standards Remedy

Sliding surface with Plating worn or peeled due to seizure or contamination Replace
sealing sections

Sliding surface ş Worn abnormality or damaged more than 0.1mm Replace

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

Sliding surface ş Worn more than 0.5mm(0.02in) or abnormality Replace

with thrust plate ş Worn less than 0.5mm (0.02in) Smooth
Cover
ş Damage due to seizure or contamination remediable
within wear limit (0.5mm((0.02in)

ş Extruded excessively from seal groove square ring Replace

- Extrusion
Square ring

ş Slipper ring 1.5mm(0.059in) narrower than seal Replace

groove, or narrower than back ring

Seal set -

1.5mm(max)
(0.059in)

ş Worn more than 0.5mm(0.02in) ~ 1.5mm(MAX) Replace

(0.059in)

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7. CYLINDER

Part name Inspecting section Inspection item Remedy

Piston rod ş Neck of rod pin ş Presence of crack ş Replace

ş Weld on rod hub ş Presence of crack ş Replace
ş Stepped part to which piston ş Presence of crack ş Replace
is attached
ş Threads ş Presence of crack ş Recondition or replace
ş Plated surface ş Plating is not worn off to ş Replace or replate
base metal
ş Rust is not present on plating ş Replace or replate
ş Scratches are not present ş Recondition, replate or replace
ş Rod ş Wear of O.D. ş Recondition, replate or replace

Cylinder tube ş Bushing at mounting part ş Wear of I.D. ş Replace

ş Weld on bottom ş Presence of crack ş Replace
ş Weld on head ş Presence of crack ş Replace

ş Weld on hub ş Presence of crack ş Replace

ş Tube interior ş Presence of faults ş Replace if oil leak is seen
ş Bushing at mounting part ş Wear on inner surface ş Replace

Gland ş Bushing ş Flaw on inner surface ş Replace if flaw is deeper than

coating

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