GROUP 6 HST PUMP (PILOT TYPE)

1. REMOVAL AND INSTALL

1) REMOVAL
If engine is running or full up pressure
into hydraulic system, absolutely does
not repair or tighten hose, fitting.
As hydraulic line explode, dangerous
accident may occur.
(1) Lowered the bucket on the ground.
13031GE18

(2) Shut off engine and raise the seat bar.

(3) Raise canopy and remove the front cover
(1, 2). 2
ö For raising and lowering of the canopy,
refer to page 4-14 of the operator's
manual. 1
(4) Disassemble hoses connected with HST
pump and auxiliary pump.
(5) Loosen the nut(3) and bolt(4).
2) INSTALL
(1) Install HST pump to frame by tightening
the nut(3) and bolts(4).
ÂTightening torque
4
- Nut(3) : 19.6Ü2.9kgfÂm
(142Ü21.0lbfÂft)
- Bolt(4) : 6.9Ü1.4kgfÂm
(49.9Ü10.1lbfÂft) 3

(2) Assemble hose connected with HST

pump and auxiliary pump.

6507AHT09B

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2. STRUCTURE (1/4)

1-1

1-13
1-12
1-32
1-26
1-36
1-31
1-37
1-38
1-37
43

11

49
30 16
32
22
21 10

49
32
6

1-14

21
47

46 7 21 3
8
6507AHT50

1 Rotary group 1-37 V-ring 16 Coupling

1-1 Rotary group 1-38 Shaft seal ling 21 Locking screw
1-12 Cradle 3 Hydraulic control 22 Locking screw
1-13 Slide ring 6 Control cartridge 30 Socket head screw
1-14 Drive shaft 7 Pressure relief valve 32 Cylinder pin
1-26 Bearing liner 8 Pressure relief valve 43 O-ring
1-31 Plain roller bearing 10 Pump housing 46 Eccentric screw
1-32 Cradle bearing assy 11 Flange bearing 47 Seal lock nut
1-36 Retaining ring 14 Internal gear pump 49 Roller bearing

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STRUCTURE (2/4)

2-14

2-37
2-31
2-36
2-26
2-32
2-12
2-13

2-1
14-10
14-19
14-1
14-13
14-6
14-12

14-5
14-9

30

12

43
14-21
14-8

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2 Rotary group 2-36 Retaining ring 14-9 Snap ring

2-1 Rotary group 2-37 V-ring 14-10 Socket head screw
2-12 Cradle 12 Bearing flange 14-12 O-ring
2-13 Slide ring 14 Internal gear pump 14-13 O-ring
2-14 Drive shaft 14-1 Intermediate flange 14-19 O-ring
2-26 Bearing liner 14-5 Coupling 14-21 Cylinder pin
2-31 Plain roller bearing 14-6 Internal gear pump 30 Socket head screw
2-32 Cradle bearing assy 14-8 Shaft key 43 O-ring

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STRUCTURE (3/4)

5 1 5 2 1

3 4 7

5 Rear pump Front pump

7 6

6507AHT102

1 Mechanical centering adjustment 5 Mechanical stroke limiter

2 DA-Control valve 6 Timing adjustment screw
3 Low pressure valve 7 Auxiliary pump
4 High pressure valve

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STRUCTURE (4/4)
R X4 Y R X4

G2

G1 S

Rear pump X3 MB B G MB B X 3 T Front pump

MA MG G2 A MG A

VIEW A 6507AHT103

Port Port name Port size

A/B High pressure ports 1 1/16 -12UN
T Case drain port 1 1/16 -12UN
MA Pressure gauge - operating pressure A 9/16 -18UNF
MB Pressure gauge - operating pressure B 9/16 -18UNF
R Air bleed 7/16 - 20UNF
X3 / X4 Control pressure ports (before the orifice) 7/16 - 20UNF
G Pressure port for auxiliary circuit 3/4 - 16UNF
MG Pressure gauge - operating pressure G 9/16 -18UNF
G1 Pressure port for auxiliary circuit 9/16 -18UNF
G2 Pressure port for auxiliary circuit 3/4 -16UNF
Y Control pressure - gauge port 9/16 -18UNF
S Boost suction port 1 5/8 -12UN

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3. ADJUSTMENT INSTRUCTIONS
1) LOW PRESSURE VALVE
(Boost pressure)
Observe safety regulations.
(1) Readjust only at operating temperature.
(2) Connect pressure gauge (60 bar) to "G1"
port.
ö Boost pressure setting is adjusted with G1
shims.
(3) Setting data is in accordance to the
specification.

6507AHT105

2) MECHANICAL "ZERO POSITION"

X3
(1) Ports X3 / X4 control pressure to the tank
open. X4
X3
(2) Connect pressure gauges (600 bar) to
MA and MB. Adjust the zero position so X4

that with at blocked drive both pressure

gauges indicate the same pressure valve.
ö Ascertain the zero position dead band.

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MB

MB

MA MA

6507AHT108-1 6507AHT108-2

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3) HP-VALVES (High pressure)
(1) Operate the valves with small pump flow
over the valves.
Check setting value. (Only for a short
moment - "Risk of over heating")

HP valves
6507AHT109

Check valve setting Marking valve setting

XXX

e.g setting after production

order

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4) ADJUSTMENT INSTRUCTIONS - DA
CONTROL
Y
(1) Check setting data. X3
(2) Operating temperature should be X3 X4
generally kept constant during the X4
checking procedure.
ö Setting data is in accordance to the
order.

G1
6507AHT111

X3 X4 Y X4 X3
R T MB G MB R G2

B B

E/G

A A

MG MA MA S
G1
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4. DISASSEMBLY AND ASSEMBLY
1) GENERAL REPAIR INSTRUCTIONS
ö Observe the following notes when
repairing hydraulic components.
(1) Close all ports of the hydraulic compo-
nents.

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(2) Replace all seals. Use only ORIGINAL

spare parts.

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(3) Check all seal and sliding surfaces for

wear.
ö Rework of sealing area (e.g. with
abrasive paper) can damage the
surface.

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(4) Fill the hydraulic units with the re-

commended hydraulic fluid before
OIL
commissioning.

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2) SEAL KITS AND SUBASSEMBLIES
(1) Seal kit for drive shaft.

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(2) Peripheral seal kit.

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(3) Inner gear pump

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(4) High pressure relief valve

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(5) Boost pressure relief valve.

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(6) DA-cartridge

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3) SEALING OF THE DRIVE SHAFT

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(1) Remove retaining ring.

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(2) Screw in tapping screw into the holes
fitted with rubber.
Pull out shaft seal with pliers.

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(3) Press-in shaft seal with bush to stop.

ö Lightly grease the seal, dust lips and
shaft seal ring.

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4) SEALING OF THE INNER GEAR PUMP

*
*
* : Mount the "chamfered side" towards the cover.
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(1) Remove fixing screws.

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(2) Pry-off cover.

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(3) Mark position.

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(4) Remove O-ring.

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(5) Pry-off the boost pump.

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1 Wear plate
2 Locating pin

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1 Kantsil-ring
2 Unloading channel
3 Locating pin 1
2
3

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(6) Fit wear plate.
ö Take care of the direction or rotation.

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(7) Fit wear plate.
Direction of rotation "Clockwise" looking
on the drive shaft.
ö Locating pin.

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* : Mount the "chamfered side" towards

the cover.

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(8) Fit boost pump.

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(9) Fit O-ring and cover plate.

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5) SEALING OF THE CONTROL PISTON
COVER
(1) Mark cover. Make a note of dimension X,
loosen counter nut, hold adjustment
screw.
X

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(2) Remove cover.

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(3) Lift off by turning the setting screw.

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(4) Check the O-ring (1), groove (2), housing

(3). 2
ö Adjustment of the correct zero position
to be carried out after installation into
the machine or on the test bench.
(see adjustment instructions)

3
1

2
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6) SEALING OF THE VALVES
(1) PSP - Valve - Sealing elements*
ÂTightening torque : 7.14kgfÂm
(51.6lbfÂft)

6507AHT98

(2) PHP - Valve - Sealing elements*

ÂTightening torque : 25.5kgfÂm
(184lbfÂft)
ö Lubricate the thread and the support
surface under the block of the high-
pressure valve. *

6507AHT99

(3) Remove valve poppet with spring.

Backup ring

O-ring

6507AHT100

(4) Install O-ring and back up ring with

auxiliary tool (sleeve). Sleeve

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(5) Remove control valve.
*Sealing elements
DA-cartridge
ÂTightening torque : 5.1kgfÂm
(36.9lbfÂft)

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(6) Do not damage the orifice diameter.

ö Check the orifice diameter.

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