Remove Hydraulic Pump

120G MOTOR GRADERS 87V05275-08359 (MACHINE) POWERED BY 3304 ENGI...
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Producto: MOTOR GRADER

Modelo: 120G MOTOR GRADER 87V05851
Configuración: 120G MOTOR GRADERS 87V05275-08359 (MACHINE) POWERED BY 3304 ENGINE
Desarmado y Armado
120G VEHICLE SYSTEMS
Número de medio -SENR7219-00 Fecha de publicación -01/10/1975 Fecha de actualización -12/10/2001
Hydraulic Pump
SMCS - 5070-15; 5070-16; 5070-11; 5070-12
Remove Hydraulic Pump

start by:
a) remove pump drive
1. Remove the treadle assembly from the governor control linkage. Remove the floor mat from the
frame.
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120G MOTOR GRADERS 87V05275-08359 (MACHINE) POWERED BY 3304 ENGI... Page 2 of 20
2. Remove the bolts that hold support (1) to the frame. Fasten a hoist to the support. Remove the seat
and support. Weight is 80 lb. (36 kg).
3. Drain the oil from the hydraulic tank and from the hydraulic pump.
4. Remove bolts (2) that hold flange (3) to the left side of the pump. Remove the O-ring seal from the
flange.
5. Remove bolts (5) that hold flange (4) to the right side of the pump. Remove the O-ring seal from
the flange.
6. Disconnect oil lines (6) from the cooler pump.
7. Disconnect oil drain line (7) from the top of the pump.
8. Fasten a hoist to the hydraulic pump.
9. Remove bolts (8) that hold the pump to the frame.
10. Remove hydraulic pump (9). Weight is 130 lb. (59 kg).
NOTICE
Be careful not to cause damage to the threads on fittings (10) in the

cooler pump.
Install Hydraulic Pump
1. Fasten a hoist to hydraulic pump (1). Lower the pump through the frame.
2. Install bolts (4) that hold the hydraulic pump to the frame.
3. Connect oil lines (3) to the cooler pump.
4. Connect oil drain line (5) to the fitting on top of the pump.
5. Install the O-ring seal in flange (2). Install the bolts that hold flange (2) to the right side of the
pump.
6. Install the O-ring seal on flange (7).
7. Install bolts (6) that hold the flange to the pump on the left side.
8. Fasten a hoist to seat (8) and the support. Put the seat and support in position on the operator
platform. Install bolts (9) that hold the support to the platform.
9. After the pump drive and cooler pump are installed on a rebuilt pump, the following procedure
must be used. If at any time during the procedure a loud noise is heard coming from the pump, stop
the procedure and disassemble the pump to find the problem.
a) Disconnect oil drain line (5) for the pump from the oil manifold block. Put a plug in the opening in
the block.
NOTE: Oil drain line (5) is the same oil line that was connected to the fitting on top of the hydraulic
pump in Step 4.
b) Open the unloader valve. Turn the engine and pump with the electric starter until oil is coming out
the return line.
NOTE: Do not run the electric starter for more than 30 seconds. Let the electric starter become cool
before it is used again.
c) With the drain line full of oil, connect it to the manifold. Start the engine and run it at low idle for
five minutes with the unloader valve open. Release the unloader valve and run the engine at low idle
for another five minutes.
d) Run the engine at high idle for five minutes. Run the engine at high idle for two minutes with a
hydraulic cylinder in an extended position.
e) Check the pump for external leakage past the seals.
Disassemble Hydraulic Pump
start by:
a) remove hydraulic pump
b) remove cooler pump
1. Thoroughly clean the outside of the pump. Drain all the oil from the pump.
2. Fasten a hoist to the pump. Put it in position on tool (A). Install two bolts and nuts to hold it.
3. Loosen the nut that holds the yoke on the shaft. Do not remove the nut.
4. Install tooling (B) on the yoke and against the shaft.
5. Loosen the yoke from its taper with tooling (B). Remove tooling (B), the nut, washer and the yoke
from the pump. Remove the key from the shaft.
6. Remove the bolts that hold housing (1) to the pump. Remove the two springs, seat (2) and the
spacer. Remove the bolts that hold the cover to housing (1). Remove the cover, the O-ring seal and
the spacer.
7. Remove the two bolts, cover (3) and the O-ring seal.
8. Install tooling (C) through the head and into the pump housing.
9. Move head (4) off the dowels in the housing and on to tooling (C).
10. Remove the head from tooling (C). Remove tooling (C) from the housing.
11. Remove port plate (6) from the dowels in the head.
NOTICE
Be careful not to cause damage to the highly machined faces of the port
plate and the head.
12. Put identification on the servo valve and on the pressure reducing valve as to their location in the
head. Remove the two valves with a soft hammer.
13. Remove bearing cup (5) from the head with tooling (F). Remove the teflon rings and the rubber
seals from the bores for the valves.
14. Remove pistons (8) and (9) from servo valve cartridge (7).
15. Remove snap ring (10) from cartridge (7) with tool (E). Remove insert (11) from the cartridge.
16. Remove sleeve (13) from the cartridge. Remove snap ring (14) from the sleeve with tool (E).
Remove spacer (12) from the sleeve.
17. Remove pin (15) with a hammer and a punch. Remove stop (16) and spool (17) from sleeve (13).
Remove setscrew (18).
17. Remove piston (19) from pressure reducing valve cartridge (20).
18. Remove plug (24), spring (23) and pistons (21) and (22) from the cartridge.
19. Put a small amount of oil on the face of tool (D). Put tool (D) on the face of the barrel.
20. Install tooling (G) and remove bearing cone (25) from the shaft. Remove tooling (G).
21. Install tooling (H) on the housing and against tool (D).
22. Tighten tooling (H) to release the pressure against the spiral snap ring. Remove the spiral snap
ring.
Do not remove the large snap ring. The large snap ring holds a large
spring in the center of the barrel which is under compression. Sudden
release of the large snap ring can cause personal injury or pump
damage.
23. Loosen tooling (H) and remove it.
24. Put tooling (I) in position over the shaft. Remove the bolts that hold the pump housing to tool (A).
Tilt housing (27) up on tool (I).
25. Remove stops (26), the O-ring seals and the shims.
26. Remove the bolts that hold covers (28) to housing (27). Install two of the bolts in the threaded
holes in covers (28). Remove the covers with the bolts.
27. Put identification on the shims and the covers for use during assembly. Remove the O-ring seal
and the shims from the cover.
28. Remove the housing from the barrel, swashplate and shaft.
29. Remove bearing (29) from the covers with tooling (J).
30. Remove the bearing cup from the housing (27) with tooling (L).
31. Remove the snap ring and the lip type seal from the housing.
32. Remove shaft (31) from swashplate (32) and from the barrel.
33. Remove bearing (30) from the shaft with tooling (J).
120G MOTOR GRADERS 87V05275-08359 (MACHINE) POWERED BY 3304 EN... Page 10 of 20
34. Put identification on the pistons and barrel (33) as to the location of the pistons in the barrel.
35. Remove swashplate (32) and the pistons from the barrel.
NOTICE
Be extra careful not to cause damage to the highly finished surfaces of

the pistons.
36. Bend the locks away from bolts (34) that hold retraction bearings (35) and the shims to the
swashplate. Remove the bolts and the locks.
37. Remove the pistons and the retraction plate. Remove pistons (38) from retraction plate (39).
38. Remove thrust plate (37) and the dowel from the swashplate.
39. Remove bearing cups (36) from the swashplate.
40. Put barrel (32) in position on a press. Put tool (D) on the face of the barrel.
41. Put the spring in compression with tooling (M) and the press. Remove the snap ring (40) with tool
(K).
42. Slowly release the pressure on the spring. Remove tooling (M).
43. Remove spacer (41), spring (42) and spacer (43) from the barrel.
Assemble Hydraulic Pump
1. Thoroughly clean all of the parts. Put a small amount of clean hydraulic oil on the parts.
2. Put plate (1) in position in the swashplate. Make sure the hole in the plate is in alignment with pin
(2) in swashplate (3).
3. Lower the temperature of bearing cups (4) and (5). Install the bearing cups in the swashplate.
4. Lower the temperature of bearing cup (7). Install the bearing cup in the pump body.
5. Install bolts (6) and (8) in the same locations from which they were removed. Install the two bolts
without the O-ring seal, shims and washers.
NOTE: These bolts are the minimum and maximum stops for the swashplate. They must be installed
in the same holes that they were removed from.
NOTE: The newer pumps have an adjustable stop for the maximum setting.
6. Put the swashplate in position in the pump body.
7. Heat bearing cones (10) in oil to a maximum temperature of 275°F (135°C). Install the bearing
cones on covers (9) and (11).
8. Install the O-ring seal on cover (11). Put cover (11) in position in the pump body and the
swashplate with .015 in. (0.38 mm) shims. Tighten bolts (12) that hold cover (11) to the pump body to
a torque of 32 lb.ft. (43.4 N·m).
9. Install cover (9) in the pump body and the swashplate. Install the bolts that hold it. Tighten the bolts
evenly in 10 lb.in. (1.13 N·) steps until the bolts have a torque of 40 lb.in. (4.52 N·m). Tighten the
bolts in a clockwise direction while moving the swashplate backward and forward.
10. Measure the gap between cover (9) and the pump body with feeler gauge (13) at the four bolt
locations. Install shims that are the same thickness as the average gap measured plus .008 in. (0.20
mm).
NOTE: If the thickness of shims is less than .005 in. (0.13 mm) or more than .025 in (0.64 mm), add
the thickness of the shims for cover (9) to the thickness of the shims for the other cover. Divide the
total thickness of the shims evenly and install the same thickness of shims on each cover.
11. Install the shims and the O-ring seal on cover (9). Install the cover on the pump body. Tighten the
bolts that hold the cover to a torque of 32 lb.ft. (43.4 N·m). Make sure the swashplate is free to move.
12. Install stop angle bar (14) from tooling (D) on the swashplate.
NOTE: The stop angle bar must be installed with the deepest point of the two angles toward the
minimum stop bolt. The bar must be at a 90° angle to a line through the center of the bearings.
13. Put gauging bar (15) from tooling (D) on the body with the end of the gauging bar against dowel
(17).
NOTE: The gauging bar must be parallel with a line through the center of the bearings.
14. Install depth gauge (16) from tooling (D) in one of the holes in the gauging bar that is directly
over the deepest angle on the stop angle bar.
15. Move the swashplate until it makes contact with maximum stop bolt (6). Measure the distance
from the top of the gauging bar to the angle on the stop angle bar. Move the depth gauge to the other
hole directly over the same angle on the stop angle bar. Measure the distance from the top of the
gauging bar to the angle on the stop angle bar.
16. Make an adjustment to the maximum stop bolt until the measured distance from the top of the
gauging bar to the angle on the stop angle bar is the same at the two holes in the gauging bar.
NOTE: When the measured distance at each of the holes in the gauging bar is the same, the deepest
angle on the stop angle bar is parrallel to the gauging bar and the adjustment for maximum stop bolt
(6) is correct.
17. Measure the distance between bolt (6) and the body with feeler gauge (13). Install shims and
washers that are the same thickness as the distance measured. Install the O-ring seal on the bolt. Put
oil on the seal. Install the bolt, shims and washers. Tighten the bolt to a torque of 80 ± 10 lb.ft. (108.5
± 13.6 N·m). Check the distance from the top of the gauging bar to the angle on the stop angle bar
again. Make an adjustment to the shims for bolt (6) if the distance is not the same at the two holes in
the gauging bar.
18. Move the swashplate until it makes contact with the minimum stop bolt. Install the depth gauge in
one of the holes directly over the smallest angle on the stop angle bar. Follow the procedures in Steps
15 through 17 and make an adjustment to minimum stop bolt (8) until the smallest angle on the stop
angle bar is parallel to the gauging bar.
NOTE: The minimum stop bolt is at its correct adjustment when the measured distance from the top
of the gauging bar is the same at the two holes in the gauging bar.
19. Remove tooling (D). Remove the covers and the shims from each side of the body. Keep the
shims with their respective covers. Remove the swashplate from the body. Put the pistons (18) in
position on the plate in the swashplate in their correct order. Install retraction plate (21) over the
pistons. Put the original amount of shims and the retraction bearings in position on the swashplate.
Install the locks and bolts (19).
20. Measure the clearance between the piston slippers and plate (1) with a feeler gauge. The clearance
must be .003 ± .001 in. (0.08 ± 0.03 mm). Add or remove shims if the clearance is not correct. Bend
locks (20) against bolts (19).
21. Put spacer (25), spring (23) and spacer (24) in position in barrel (22).
22. Put barrel (22) in position on a press. Put tooling (A) in position on the face of the barrel.
23. Put spring (23) in compression with the press. Install the snap ring (26) with tooling (B). Remove
the barrel from the press.
NOTE: The guard for the press has been removed for photo illustration.
24. Put the barrel and tooling (A) in position on tool (C) as shown.
25. Put the pistons in their correct locations in the barrel.
26. Heat bearing cone (28) in oil to a maximum temperature of 275°F (135°C). Install bearing cone
(28) on shaft (27).
27. Put the shaft and the bearing cone in position in the swashplate and the barrel.
28. Put pump body (29) in position over the swashplate, barrel and the shaft.
29. Tilt the pump on tool (C). Keep the tool against the barrel face and lower the pump into position
on tool (E). Install the bolts and the nuts that hold the pump to tool (E).
30. Remove tool (C). Push the swashplate, barrel and the shaft into the pump body.
31. Put correct amount of shims (31) in position on the covers. Install O-ring seals (30) on the covers.
Put a small amount of clean oil on the seals. Put the covers in position in the body. Install the bolts
that hold the covers.
32. Install tooling (F) on the pump body and against tool (A) as shown.
NOTICE
Tool (A) must be used to prevent damage to the face of the barrel.
33. Tighten the nuts on tooling (F) to put the spring in the barrel in compression. Install spiral snap
ring (32) on the shaft. Slowly loosen the nuts to release the compression on the spring. Remove
tooling (F).
34. Heat bearing cone (33) in oil to a maximum temperature of 275°F (135°C).
35. Install bearing cone (33) on the shaft.
36. Lower the temperature of bearing cup (34). Install bearing cup (34) in the head.
TYPICAL EXAMPLE
37. Install seven teflon rings (35) and seven rubber seals (36) in head (37). Install the teflon rings in
the outer grooves toward the outside surfaces of the head. Install the teflon rings in the inner grooves
toward the center of the head. This will make sure the rubber seals are toward the pressure holes
(cavities).
38. Put spool (43) in position in sleeve (40). Install stop (4r ) on the spool. Install pin (39) in the stop
and spool.
39. Install spacer (41) in the sleeve. Install snap ring (38).
40. Install insert (45) in cartridge (44). Install snap ring (46) in the cartridge with tool (G).
41. Install sleeve (40) in cartridge (44). Install the spacer in the cartridge.
42. Put piston (48) in position in piston (47). Install the pistons in the cartridge.
43. Put 9S3263 Thread Lock on the threads of the setscrew and install the setscrew in the cartridge.
44. Put piston (49) in position in cartridge (50).
45. Put pistons (51) and (53) in position in the cartridge. Install spring (52) and plug (54) in the
cartridge.
46. Put a small amount of clean SAE 10 oil on the seals and the rings in head (37). Put servo valve
cartridge (44) and pressure reducing valve cartridge (50) in their correct positions in the head.
47. Remove the cartridges. Check the rings and the seals in the head for damage. If the seals and rings
are damaged, remove them and install new seals and rings (see Step 37). Check the cartridges for
scratches and remove the scratches if they are present. Install the cartridges in the head.
48. Put a small amount of clean SAE 10 oil on the face of head (37). Put port plate (55) in position on
the head. Make sure the holes in the port plate are in alignment with the dowels in the head.
49. Install tooling (H) in the pump body. Put gasket (56) in position over tooling (H) and on the pump
body. Install head (37) on the pump body. Install the bolts and the lockwashers that hold it. Remove
tooling (H).
50. Install the O-ring seal in cover (57). Install the O-ring seal in housing (58).
51. Put spacer (61) in position on cover (57). Install small spring (62), the shims and seat (63) on
spacer (61) and cover (57).
52. Install housing (58) on cover (57). Install large spring (64) and spacer (66) over the small spring
and the seat.
53. Install the two bolts and washers through cover (57) and housing (58). Install the bolts, cover and
housing on the head.
54. Install the O-ring seal on plug (59). Install the plug in the head. Install O-ring seal (60) in cover
(65). Install the bolts and cover (65) on the head.
55. Install the seal in the pump with tool (J). Install the seal with the large lip and the spring toward
the inside of the pump.
56. Install the snap ring that holds the seal in the pump with tool (B).
57. Install covers over all the openings on the pump. Fill the pump with SAE 10 oil until it is over one
half full.
58. Install nut (68) on the end of the pump shaft. Turn the pump shaft with a socket and a torque
wrench. The torque needed to start the shaft turning must not be more than 10 lb.ft. (13.6 N·m). The
torque needed to keep the shaft turning must not be more than 7 lb.ft. (9.5 N·m).
NOTE: If the torque values are higher than the above specifications, the pump must be disassembled
and the problem corrected.
59. See HYDRAULIC SYSTEM AND STEERING SPECIFICATIONS, FORM NO. REG01682 for
test specifications.
60. Remove the nut from the shaft. Install yoke (67), the washer and nut (68) on the shaft. Make sure
the key is in the groove in the shaft.
61. Tighten nut (68) to a torque of 180 ± 10 lb.ft. (244.0 ± 13.6 N·m).
end by:
a) install cooler pump
b) install hydraulic pump
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Remove Hydraulic Pump

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120G MOTOR GRADERS 87V05275-08359 (MACHINE) POWERED BY 3304 ENGI...

Producto: MOTOR GRADER

Remove Hydraulic Pump

a) remove pump drive

6. Disconnect oil lines (6) from the cooler pump.

8. Fasten a hoist to the hydraulic pump.

9. Remove bolts (8) that hold the pump to the frame.

Be careful not to cause damage to the threads on fittings (10) in the

Install Hydraulic Pump

3. Connect oil lines (3) to the cooler pump.

6. Install the O-ring seal on flange (7).

e) Check the pump for external leakage past the seals.

Disassemble Hydraulic Pump

a) remove hydraulic pump

b) remove cooler pump

4. Install tooling (B) on the yoke and against the shaft.

23. Loosen tooling (H) and remove it.

Be extra careful not to cause damage to the highly finished surfaces of

39. Remove bearing cups (36) from the swashplate.

Assemble Hydraulic Pump

6. Put the swashplate in position in the pump body.

25. Put the pistons in their correct locations in the barrel.

35. Install bearing cone (33) on the shaft.

44. Put piston (49) in position in cartridge (50).

a) install cooler pump

b) install hydraulic pump

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