GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

9 5 6 4 7 8 (210-7) 7-21

Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & cylinder Replace piston
d D 0.039 0.067
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 piston & shoe.
ɺ
(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

plate(5) & spherical h H
23.0 22.0 Replace retainer
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), & 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 ÂExistence of scratch, rusting or corrosion. ÂIn 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 ÂExistence of scratch, gnawing, rusting or
corrosion.
ÂO-ring seal sections at both ends.
ÂInsert spool in casing hole, rotate and
reciprocate it.
ÂReplacement when its outside sliding
section has scratch(Especially on seals-
contacting section).
ÂReplacement when its sliding section has
scratch.
ÂCorrection or replacement when O-ring is
damaged or when spool does not move
smoothly.

Poppet ÂDamage of poppet or spring ÂCorrection or replacement when sealing is

incomplete.
ÂInsert poppet into casing and function it. ÂNormal when it can function lightly without
being caught.

Around spring ÂRusting, corrosion, deformation or breaking ÂReplacement for significant damage.
of spring, spring seat, plug or cover.

Around seal ÂExternal oil leakage. ÂCorrection or replacement.

for spool
ÂRusting, 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.
negative control
relief valve ÂContacting face of poppet. ÂReplacement when damaged.
ÂAbnormal spring. ÂReplacement.
ÂO-rings, back up rings and seals. Â100 replacement in general.

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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
6.5 6.0
bushing (H) sperical bushing

Thickness of friction plate(h) 4.0 3.6 Replace

H
h
ɺ

2) SLIDING PARTS

Part name Standard roughness Allowable roughness Remark

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

(LAPPING)

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

(LAPPING)

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

(LAPPING)

Valve plate 0.8-Z(Ra=0.2) 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

Replace assembly
Thickness of shoe(t) 4.5 4.3
of piston and shoe

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

Thickness of friction plate 3.0 2.6 Replace

)
T I

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 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more 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 10ʂm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.

Push rod

͚7

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 When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
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.

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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 : 30kgf/cm2
drop. Oil viscosity : 23cSt

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

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 When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
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.

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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 0.1mm Replace

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

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

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

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

with thrust plate.
Cover ÂWorn less than 0.5mm(0.02in). Smooth
ÂDamage due to seizure or contamination remediable Replace
within wear limit (0.5mm)(0.02in).

ÂExtruded excessively from seal groove square ring. Replace

- Extrusion
Square ring

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

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

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

(0.059in)

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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
ÂStepped part to which piston ÂPresence of crack ÂReplace
is attached.
ÂThreads ÂPresence of crack ÂRecondition or replace
ÂPlated surface ÂPlating is not worn off to base ÂReplace or replate
metal.
ÂRust is not present on plating. ÂReplace or replate
ÂScratches are not present. ÂRecondition, 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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