GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

B B

9 5 6 4 7 8 21097MP01

Standard Recommended
Part name & inspection item replacement Counter measures
dimension value

Clearance
between piston (1) & Replace piston
d D 0.039 0.067
cylinder bore (2) or cylinder.
(D-d)

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

Free height of cylinder

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

Combined height of set

h H
plate (5) & spherical Replace retainer
23.0 22.0
bushing (6) or set plate.
(H-h)

Surface roughness for valve Surface roughness

necessary to be corrected 3z
plate (sliding face) (7,8),
swash plate (shoe plate Lapping
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 ÂExistence of scratches, rust or corrosion. Â
In case of damage in following section,
replace casing.
- Sliding sections of casing hole and spool,
especially land sections applied with held
pressure.
- Seal pocket section where spool is inserted.
- Sealing section of port where O-ring
contacts.
- Sealing section of each relief valve for main
and port.
- Sealing section of plug.
- Other damages that may damage normal
function.

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

Poppet ÂDamage of spring ÂReplacement.

ÂDamage of poppet Â
Correction or replacement when sealing is
incomplete.
ÂInsert poppet into casing and function it. Â
Normal when it can function lightly and
smoothly without sticking.

Spring and related Â
Rusting, corrosion, deformation or breakage ÂReplacement for significant damage.
parts of spring, spring seat, plug or cover.

Around seal ÂExternal oil leakage. ÂCorrection or replacement.

for spool Â
Rusting, corrosion or deformation of seal ÂCorrection or replacement.
plate.

Main relief valve, ÂExternal rusting or damage. ÂReplacement.

port relief valve & ÂContacting face of valve seat. ÂReplacement when damaged.
posi-nega
conversion valve ÂContacting face of poppet. ÂReplacement when damaged.
ÂO-rings and back up rings. ÂReplacement in principle.

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3. SWING DEVICE
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value

Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058 cylinder block

Replace assembly
Play between piston and shoe caulking section (ɺ) 0 0.3 of piston and shoe

Replace assembly
Thickness of shoe (t) 5.5 5.3 of piston and shoe

Replace set of
Combined height of retainer plate and spherical retainer plate and
bushing (H) 6.5 6.0
sperical bushing

Thickness of friction plate (h) 4.0 3.6 Replace

h H
t
ɺ

2507A7MS04 2507A7MS05

2) SLIDING PARTS

Part name Standard roughness Allowable roughness Remark

0.8-Z (Ra=0.2)
Shoe 3-Z (Ra=0.8)
(LAPPING)

0.4-Z (Ra=0.1)
Shoe plate 3-Z (Ra=0.8)
(LAPPING)

1.6-Z (Ra=0.4)
Cylinder 12.5-Z (Ra=3.2)
(LAPPING)

0.8-Z (Ra=0.2)
Valve plate 6.3-Z (Ra=1.6)
(LAPPING)

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4. TRAVEL MOTOR
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value

Replace piston or
Clearance between piston and cylinder block bore 0.025 0.050
cylinder block

Replace assembly
Play between piston and shoe caulking section (T) 0 0.3
of piston and shoe

Thickness of shoe (t) Replace assembly

4.5 4.3
of piston and shoe

Replace set of set

Combined height of set plate and ball guide (H) 7.3 7.0 plate and ball guide

Thickness of friction plate 3.0 2.6 Replace

)
I
T

2) SLIDING PARTS

Part name Standard roughness Remark

Shoe 0.8S -

Shoe plate 0.8S -

Cylinder 0.8S -

Valve plate 0.8S -

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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 1000 cc/m at neutral handle Primary pressure : 40 kgf/cm2
position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt

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

Push rod

͚7

1 mm

This is to be replaced when the top end has worn

more than 1 mm.

Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2 mm 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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6. RCV PEDAL
Maintenance
Criteria Remark
check item

Leakage The valve is to be replaced when the leakage effect Conditions :

to the system. For example, the primary pressure Primary pressure : 40 kgf/cm2
drop. Oil viscosity : 23 cSt

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

Push rod

͚7

1 mm

This is to be replaced when the top end has worn

more than 1 mm.

Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2 mm 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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7. TURNING JOINT
Part name Maintenance standards Remedy

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

Sliding surface ÂWorn abnormality or damaged more than 0.1 mm Replace

between body and (0.0039 in) in depth due to seizure contamination.
Body, stem other than
ÂDamaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.
Stem sealing section.

Sliding surface ÂWorn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
ÂWorn less than 0.5 mm (0.02 in). Smooth
Â
Damage due to seizure or contamination remediable Smooth
within wear limit (0.5 mm) (0.02 in).

Sliding surface ÂWorn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
ÂWorn less than 0.5 mm (0.02 in). Smooth
Cover
Â
Damage due to seizure or contamination remediable Replace
within wear limit (0.5 mm) (0.02 in).

ÂExtruded excessively from seal groove square ring. Replace

- Extrusion
Square ring

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

groove, or narrower than back ring.
Seal set
-
1.5mm (max.)
(0.059 in)

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

(0.059 in)

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8. CYLINDER
Part name Inspecting section Inspection item Remedy

Piston rod ÂNeck of rod pin ÂPresence of crack ÂReplace

ÂWeld on rod hub ÂPresence of crack ÂReplace
Â
Stepped part to which piston ÂPresence of crack ÂReplace
is attached.
ÂThreads ÂPresence of crack ÂRecondition or replace
ÂPlated surface Â
Plating is not worn off to base ÂReplace or replate
metal.
ÂRust is not present on plating. ÂReplace or replate
ÂScratches are not present. Â
Recondition, replate or replace
ÂRod ÂWear of O.D. ÂRecondition, replate or replace
ÂBushing at mounting part ÂWear of I.D. ÂReplace

Cylinder tube ÂWeld on bottom ÂPresence of crack ÂReplace

ÂWeld on head ÂPresence of crack ÂReplace
ÂWeld on hub ÂPresence of crack ÂReplace
ÂTube interior ÂPresence of faults ÂReplace if oil leak is seen
ÂBushing at mounting part ÂWear on inner surface ÂReplace

Gland ÂBushing ÂFlaw on inner surface ÂReplace if flaw is deeper

than coating

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