P Series Hydrostatic Pumps Service and Repair Manual: PW PK

PK
PW
PG/PE
PR
PJ
PC
P Series
Hydrostatic Pumps
Service and Repair Manual
BLN-52503
August, 2010
Table of Contents
Section Page
Description and Operation.................................................................................................. 1
Introduction................................................................................................................................................... 1
General Description...................................................................................................................................... 1
External Features....................................................................................................................................... 2-7
PC Series............................................................................................................................................... 2
PG/PE Series......................................................................................................................................... 3
PJ Series................................................................................................................................................ 4
PK Series................................................................................................................................................ 5
PR Series............................................................................................................................................... 6
PW Series............................................................................................................................................... 7
Hydraulic Schematic.................................................................................................................................. 8-9
PC, PG, PE, PJ, PK and PR Series....................................................................................................... 8
PW Series............................................................................................................................................... 9
Graphical Schematic . ................................................................................................................................ 10
Technical Specifications...............................................................................................................................11
Product Identification.................................................................................................................................. 12
Safety................................................................................................................................... 13
Personal Safety........................................................................................................................................... 13
Tool Safety.................................................................................................................................................. 13
Work Area Safety........................................................................................................................................ 13
Servicing Safety.......................................................................................................................................... 13
Troubleshooting............................................................................................................ 14-15
P Series Flow Test Kit Instructions......................................................................................................... 16-17
Service and Maintenance............................................................................................. 18-20

External Maintenance................................................................................................................................. 18
Service and Maintenance Procedures........................................................................................................ 18
Fluids.......................................................................................................................................................... 18
Fluid Volume and Level............................................................................................................................... 19
Fluid Change............................................................................................................................................... 19
Filters.......................................................................................................................................................... 19
Purging Procedures.................................................................................................................................... 19
Return to Neutral Setting............................................................................................................................ 20
Repair........................................................................................................................... 21-126
PC Series Pump.................................................................................................................................... 21-36
PG/PE Series Pump.............................................................................................................................. 37-54
PJ Series Pump..................................................................................................................................... 55-72
PK Series Pump..................................................................................................................................... 73-90
PR Series Pump.................................................................................................................................. 91-108
PW Series Pump................................................................................................................................ 109-126
Glossary of Terms..................................................................................................... 127-128

FOREWORD
Headquartered in Sullivan, Illinois, Hydro-Gear Some repair procedures require that the pump
is a world leader in the design, manufacture, and be removed from the vehicle.
service of quality hydrostatic transaxles for the
lawn and garden industry. The mission of our This is not a certification, test or study guide for
company is to be recognized by our customers a certification test. If a technician is interested in
and the industry as a world-class supplier and certification they should contact an agent
the quality leader in everything we do. representing the OPEESA (Outdoor Power
Equipment and Engine Service Association)
This Service and Repair Manual is designed to (860-767-1770) or their Hydro-Gear Distribu-
provide information useful in servicing the tor. Many distributors will be hosting certifica-
Hydro-Gear 6cc (0.37 cu in.) PC Series, the 10 tion testing. These study guides will cover most
cc (0.61 cu in.) PG Series, the 12 cc (0.73 cu of the products and manufacturers in our indus-
in.) PJ Series, the 16 cc (0.98 cu in.) PR Series, try.
and the 21 cc (1.28 cu in.) PW Series pumps.
For more information about Hydro-Gear or our
Also included is a glossary of terms that are products, please contact your Central Service
frequently used throughout the industry and in Distributor, or call our Customer Service Depart-
Hydro-Gear service publications. Understand- ment at (217) 728-2581.
ing terminology is very important!
It is necessary, and good shop practice, that your
service area be equipped with proper tools and
the mechanics to be supplied with the latest
information available. All repair procedures illus-
trated in this guide are suggested, but
preferred methods of repair.
iv P Series
Section 1. Description and Operation
Introduction
The purpose of this manual is to provide informa- In some applications of the P Series Pumps, it is
tion useful in servicing the Hydro-Gear PC, PG, PJ, desirable to move the machine for short distances at
PK, PR and PW Pumps. This manual includes the low speeds without operating the engine. A screw-
pumps general descriptions, hydraulic schematics, type bypass valve is utilized in the pumps to permit
technical specifications, servicing and troubleshoot- movement of the machine. The bypass valve is fully
ing procedures for the pumps. opened when unscrewed two (2) turns maximum.
The bypass valve allows oil to be routed from one
The P Series Pumps normally will not require side of the pump/motor circuit to the other, thus
servicing during the life of the vehicle in which it allowing the motor to turn with minimal resistance.
is installed. Should other servicing be required, An increase in resistance will occur with movement
the exterior of the pump will need to be thoroughly at higher speeds. The bypass valve must be fully
cleaned before beginning most procedures. closed during normal operation.
General Description
The P Series Pumps can be combined with wheel WarnInG
motors and other remotely located units. These
pumps provide an infinitely variable speed range actuating the bypass will result in the
between zero and full displacement in both forward loss of hydrostatic braking capacity. the
and reverse modes of operation. machine must be stationary, on a level
surface and in neutral when actuating the
The P Series Pumps are of the axial piston design,
utilizing spherical nosed pistons. A compression bypass.
spring, located inside each piston, holds the nose
of the piston against a thrust bearing race. Additionally, some pumps may be equipped with
an Auxiliary Pump. The Auxiliary incorporates the
The variable displacement pump features a cradle
principles of the charge gerotor assembly and pro-
swashplate with a direct-proportional displacement
vides the capability of an external auxiliary flow for
control. Movement of the directional control shaft
an alternate hydraulic circuit to operate accessories
produces a proportional swashplate movement and
without loss of drive.
a change in pump flow and/or direction.
Reversing the direction of the angle of the swash-

plate reverses the flow of oil from the pump and thus
reverses the direction of motor output rotation.
A fixed displacement gerotor charge pump is

provided in P Series Pumps. Oil from an external
reservoir and filter is pumped into the closed loop
by a charge pump. Fluid not required to replenish
the closed loop flows either into the pump housing
through a cooling orifice, or back to the charge pump
inlet through the charge pressure relief valve.
Check or shock valves are included in the pump end

cap to control the makeup oil flow for the system.
The size and type of check valve can play an im-
portant role on the system pressure, response, and
amount of heat generated, due to the recirculation
of makeup oil flow. Shock valves are factory preset
pressure regulating check valves.
P Series 1
EXTERNAL FEATURES - PC Series
Figure 1. PC Pump with Standard Charge Pump
2 P Series
EXTERNAL FEATURES - PG Series
SAE A PAD
FLANGE STYLE
INLET
INPUT SHAFT
CHARGE
PRESSURE
DIAGNOSTIC
PORT
A and B
PORTS
STANDARD CHECK CHARGE TRUNNION

STANDARD CHECK
VALVE OR SCR COVER ARM
VALVE OR SCR
CASE DRAIN
CASE DRAIN
OPTION
OPTION BYPASS VALVE
Figure 2. PG Pump With Standard Charge Pump
P Series 3
EXTERNAL FEATURES - PJ Series
Figure 3. PJ Pump with Standard Charge Pump
4 P Series
EXTERNAL FEATURES - PK Series
Figure 4. PK Pump With Standard Charge Pump
P Series 5
EXTERNAL FEATURES - PR Series
SAE A PAD
FLANGE STYLE
BYPASS
VALVE
TRUNNION ARM
INPUT SHAFT INLET
CHARGE PRESSURE
DIAGNOSTIC PORT
A and B PORTS
SYSTEM CHECK VALVE SYSTEM CHECK VALVE

OR SHOCK VALVE OR SHOCK VALVE
CHARGE
CASE DRAIN COVER CASE DRAIN
BYPASS VALVE
Figure 4. PR Pump With Standard Charge Pump
6 P Series
EXTERNAL FEATURES - PW Series
SAE B PAD
FLANGE STYLE
TRUNNION ARM
CHARGE
A and PRESSURE
B DIAGNOSTIC
INPUT SHAFT PORTS PORT
BYPASS VALVE CASE DRAIN
STANDARD CHECK VALVE CHARGE STANDARD CHECK VALVE

OR SHOCK VALVE COVER OR SHOCK VALVE
Figure 5. PW Pump With Standard Charge Pump
P Series 7
Hydraulic Schematic
System Check & Relief Valve Options

Orifice size Relief pressure (psi) Relief pressure (bar)
OR OR
No Bleed Check ball Check ball
.024 Bleed 1740 120
.031 Bleed 2320 160
.044 Bleed 2900 200
PORT A
SYSTEM
CHARGE
RELIEF
PORT B
CHARGE
CHARGE PUMP DIAGNOSTIC BYPASS VALVE
INLET BLEED OPTIONS
1) NO BLEED ORIFICE
2) .031 BLEED ORIFICE
Figure 6. PC, PG, PJ, PK and PR Pumps with Standard Charge Pump


.024 Bleed 1740 120
.031 Bleed 2320 160
.044 Bleed 2900 200
AUXILIARY RETURN OR OR
AUXILIARY DISCHARGE
PORT A
650 PSI
AUX RELIEF
SYSTEM
CHARGE
RELIEF
PORT B
CHARGE DIAGNOSTIC
BYPASS VALVE
CHARGE PUMP BLEED OPTIONS:
INLET 1) NO BLEED ORIFICE
2) .031 BLEED ORIFICE
Figure 7. PC, PG, PJ, PK and PR Pumps with AuxiliaryCharge Pump
8 P Series
Hydraulic Schematic

.024 Bleed 1740 120 OR
.031 Bleed 2320 160
.044 Bleed 2900 200
PORT A
PORT B
BYPASS VALVE
CHARGE DIAGNOSTIC
BLEED OPTIONS
CHARGE PUMP 1) NO BLEED ORIFICE
INLET 2) .031 BLEED ORIFICE
Figure 8. PW Series Pump With Standard Charge Pump


.024 Bleed 1740 120 OR
.031 Bleed 2320 160
.044 Bleed 2900 200
AUXILIARY
AUXILIARY AUXILIARY
DISCHARGE
DISCHARGE RETURN AUXILIARY
RETURN
PORT A
650 PSI
CHG
REL
PORT B
BYPASS VALVE
BLEED OPTIONS
CHARGE 1) NO BLEED ORIFICE
DIAGNOSTIC 2) .031 BLEED ORI-
CHARGE PUMP
FICE
INLET
Figure 9. PW Series Pump With Auxiliary Charge Pump
P Series 9
GRAPHICAL Schematic
Figure 10. P Series Pump With Standard Charge Pump
Figures 10 represents a graphical schematic of the As the angle of the pump swashplate is increased,
P Series Pump with standard charge pump. Figure the amount of oil being pumped will increase and
10 provides a graphical illustration of the hydraulic cause a higher speed output of the wheel motor.
oil circuit. Reversing the angle of the swashplate will reverse
the direction of the oil flow. During the operation
The input shaft and pump cylinder block are turned of the pump, fluid is lost from the hydraulic loop
in one direction only by the engine/drive belt/pulley through leak paths designed into the product for
combination or direct drive gear box. lubrication and cooling purposes (around pistons,
The oil is drawn through an external filter by the under the rotating cylinder block, etc.). This lost
charge pump. The filter prevents contaminants fluid returns to the reservoir through the case drain.
within the reservoir from entering into the charge This fluid must be made up in the loop. The charge
pump gerotor. pump makes up this fluid loss.
The charge pump supplies fluid to keep the closed The makeup flow is controlled (or directed) by the
loop pressurized, preventing cavitation and provid- system check valves. The check valves are used
ing cooling oil flow for the system. to direct makeup fluid into the low pressure side
of the closed loop. Each check valve will either be
The charge relief valve is used to maintain charge held open or closed, depending upon the direction
at a predetermined pressure. of the vehicle operation: Closed in a pressurized
system passage, open in a low pressure, charged
Output of the system oil flow is controlled by the system passage.
direction and amount that the swashplate is
angled. As the pump pistons compress, they force
oil into one of two passageways (A or B) in the
system hydraulic circuit. Oil is supplied externally
under pressure to an external load, (e.g., a vehicle
wheel motor).
10 P Series
TECHNICAL SPECIFICATIONS
Product Type PC PG PJ/PK PR PW
Displacement in3/rev 0.37 0.62 0.73 0.97 1.33

[cc/rev] [6.1] [10.2] [12] [16] [21.8]
Input Speed
Maximum Unloaded rpm 3600 3600 3600 3600 3600
Minimum Loaded rpm 1800 1800 1800 1800 1800
System Operating Pressure

Continuous psi 750 1000 1000 1250 1250
[bar] [51] [70] [70] [86] [86]
Intermittent psi 1750 2100 2100 2500 2500
[bar] [120] [145] [145] [172] [172]
Peak psi 2500 3500 3500 3750 3750
[bar] [172] [240] [240] [260] [260]
Pump Performance
@2400 rpm/1000 psi gpm [l/min] 3.6 [13.6] 6.1 [23.1] 7.1 [26.8] 9.6 [36.3] 13.1 [49.6]
@3000 rpm/1000 psi gpm [l/min] 4.5 [17.0] 7.6 [28.8] 8.9 [33.6] 12 [45.4] 16.4 [62.1]
@3600 rpm/1000 psi gpm [l/min] 5.4 [20.4] 9.2 [34.8] 10.8 [40.8] 14.4 [54.5] 19.6 [74.2]

Case Pressure
Maximum @ Cold Start psi [bar] 10 [0.7] 10 [0.7] 10 [0.7] 25 [1.7] 25 [1.7]
Continuous - Max. psi [bar] 4 [0.3] 4 [0.3] 4 [0.3] 10 [0.7] 10 [0.7]
Inlet Vacuum
Maximum Continuous Inches Mercury 4 4 4 4 4
Charge Pump Displacement(s)

in3/rev 0.13 0.11/0.13 0.19 0.13/0.19 0.13/0.19
[cc/rev] [2.1] [1.9/2.1] [3.2] [2.1/3.2] [2.1/3.2]
Auxiliary Pump Displacement

in3/rev 0.19 0.19 0.19 0.19 0.19
[cc/rev] [3.2] [3.2] [3.2] [3.2] [3.2]
Auxiliary Pump Relief Setting

psi 650 650 650 650 650
[bar] [45] [45] [45] [45] [45]
Auxiliary Pump Performance

@3200 rpm, 500 psi, 70 SUS
[13 Cst] oil, & 180F gpm 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0 1.8 - 2.0
[l/min] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6] [6.8 - 7.6]
Control Torque Required to Stroke Pump

[Approximate - 20External Stroke Angle]
lb-in / 1000 psi 75 85 85 95 105
[N-m / 70 bar] [8.5] [9.6] [9.6] [10.7] [11.9]
lb-in / 500 psi 55 60 60 75 85
[N-m / 35 bar] [6.2] [6.8] [6.8] [8.5] [9.6]
Pump Oil Temperature

Maximum Intermittent (hottest point) F 230 230 230 230 230
[C] [110] [110] [110] [110] [110]
Normal Operating Range F -10 to 200 -10 to 200 -10 to 200 -10 to 200 -10 to 200
[C] [-23 to 93] [-23 to 93] [-23 to 93] [-23 to 93] [-23 to 93]
Fluid Viscosity Limits @ 230F [110C]

Optimum SUS [cSt] 70 [13] 70 [13] 70 [13] 70 [13] 70 [13]
Minimum SUS [cSt] 55 [9] 55 [9] 55 [9] 55 [9] 55 [9]
Weight of Unit
lbs [kg] 7 [3.2] 8 [3.6] 12.65 [5.7] 12 [5.4] 14 [6.3]
Inlet Filtration Requirement

Nominal micron 25 25 25 25 25
Table 1: P Series Pump Technical Specifications

P Series 11
PRODUCT IDENTIFICATION
The label in Figure 11 is located on the pump housing. It identifies the model and configuration of the
pump.
HYDRO-GEAR
model number PC-AGCC-MV1X-XXXX
4 244 P1 0192 MADE IN U.S.A.

year Built
Serial number
date (unique number for that model - for that day)
(Julian - day of year)
type of Product and Build Information
Figure 11. P Series Pump Configuration Label
12 P Series
Section 2. Safety
This symbol points out important safety Wear appropriate clothing. Loose or hanging cloth-
instructions which, if not followed, could en- ing or jewelry can be hazardous. Use the appropri-
danger the personal safety and/or property ate safety equipment, such as eye and hearing
of yourself and others. Read and follow all instruc- protection, and safety-toe and slip-proof shoes.
tions in this manual before attempting maintenance
on your P Series Pump. When you see this symbol Never use compressed air to clean debris from
- HEED ITS WARNING. yourself or your clothing.
TOOL safety
Warning Use the proper tools and equipment for the task.
Inspect each tool before use and replace any tool

potential for serious injury that may be damaged or defective.
Inattention to proper safety, operation, or WORK AREA SAFETY
maintenance procedures could result in
personal injury, or damage to the equip- Keep the work area neat and orderly. Be sure it is
ment. Before servicing or repairing the P well lit, extra tools are put away, trash and refuse
Series Pump, read fully and understand are in the proper containers, and dirt or debris
have been removed from the working areas of the
the safety precautions described in this
machine.
section.
The floor should be clean and dry, and all extension
cords or similar trip hazards should be removed.
Personal safety
Certain safety precautions must be observed while Servicing Safety
servicing or repairing the P Series Pump. This sec-
Certain procedures may require the vehicle to be
tion addresses some of these precautions but must
disabled in order to prevent possible injury to the
not be considered an all-inclusive source on safety
servicing technician and/or bystanders.
information. This section is to be used in conjunc-
tion with all other safety material which may apply, The loss of hydrostatic drive line power may result
such as: in the loss of hydrostatic braking capability.
Other manuals pertaining to this machine Some cleaning solvents are flammable. Use only
Local and shop safety rules and codes approved cleaning materials: Do not use explosive
or flammable liquids to clean the equipment.
Governmental safety laws and regulations
To avoid possible fire, do not use cleaning solvents
Be sure that you know and understand the equip- in an area where a source of ignition may be pres-
ment and the hazards associated with it. Do not ent.
place speed above safety.
Discard used cleaning material in the appropriate
Notify your supervisor whenever you feel there is containers.
any hazard involving the equipment or the perfor-
mance of your job.
Never allow untrained or unauthorized personnel to

service or repair the equipment.
P Series 13
Section 3. Troubleshooting
In many cases, problems with the P Series Pump

WARNING are not related to a defective pump but are caused
by slipping drive belts, partially engaged bypass
Do not attempt any servicing or ad- valves, and loose or damaged control linkages. Be
justments with the engine running. sure to perform all operational checks and adjust-
Use extreme caution while inspecting ments outlined in Section 3 before assuming the
the drive belt assembly and all vehicle pump is malfunctioning. Table 2 below provides
linkage! a troubleshooting checklist to help determine the
cause of operational problems.
Follow all safety procedures outlined in
the vehicle owners manual!

Possible Cause Corrective Action
VEHICLE DOES NOT DRIVE/TRACK STRAIGHT
Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure
Control linkage bent, loose or out of adjustment Repair, adjust or replace vehicle linkage
Bypass loose Tighten pump bypass per External Maintenance

step 9, page 17
Inlet Leak Check all external lines and connections to pump

inlet
UNIT IS NOISY
Excessive input speed Adjust input speed above 1800 rpm and below
3600 rpm
Oil level low or contaminated oil Fill reservoir to proper level or change oil
Excessive loading Reduce vehicle load
Air trapped in hydraulic system Purge hydraulic system per Purging Procedures
on page 18

step 9, page 17
Inlet leak, line or filter partially blocked or Check all external lines and connections
and filter
damaged to pump inlet
Table 2. Pump Troubleshooting Checklist
14 P Series

Possible Cause Corrective Action
UNIT HAS NO/LOW POWER
Engine speed low Adjust to correct rpm setting
Control linkage bent, loose or out of adjustment Repair or replace vehicle linkage
Drive belt slipping or pulley damaged Repair or replace drive belt or pulley

step 9, page 17
on page 18
Inlet leak Check all external lines and connections to pump

inlet
Inlet filter clogged Replace inlet filter
Suspected internal damage Check pump by performing Flow Test on page 15
UNIT OPERATING HOT
Debris buildup Remove debris from pump and fan
Cooling fan or heat exchanger damaged Repair or replace cooling fan or heat exchanger
on page 18
Inlet leak Check all external lines and connections to pump

inlet
PUMP LEAKS OIL
Damaged seals and gaskets Remove debris, replace seals
on page 18
P Series 15
P SERIES FLOW TEST KIT INSTRUCTIONS BLN-51334 July 2010
(This Instruction Sheet supersedes all previous flow testing instructions)
Description: P Series Flow Test Kit (Part Number 70661)

(Part Number 70661 Supersedes Part Numbers 70511 and BB-76810)
Purpose: The design purpose of the P Series Flow Test Kit is to allow the customer to isolate the pump from the
wheel motor and determine if the pump is acceptable. The following information can be used to install and test the
pump by simulating a wheel motor load.
WARNING WARNING
Certain procedures require the vehicle engine Do not attempt any adjustments with the engine
to be operated and the vehicle to be raised off running. Use extreme caution while working in
of the ground. To prevent possible injury to the or around all vehicle linkage! High temperatures
servicing technician and/or bystanders, insure can be generated. Follow all safety procedures
the vehicle is properly secured. outlined in the vehicle owners manual!
INSTALLATION AND TESTING PROCEDURES:

1. Disconnect the system hoses at the wheel motor, or system hoses from the pump and connect the
P Series Flow Test Kit. (Special care should be taken to prevent contamination debris from entering
pump or wheel motor system ports)
Note: Using the Bi-Directional Flow Test Kit, determination of directional flow is not necessary. The flow
meter may be connected in either direction into the forward and reverse high pressure system lines.
CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the
vehicles high pressure system lines. Failure to perform this properly could result in bodily injury.
TESTING PROCEDURES:
1. Raise the drive tires off of the ground. Block the remaining tires on the ground to prevent accidental
vehicle movement.
2. Open the restriction valve all the way.
3. Make certain all external pump directional control stops are removed or backed off on the vehicle
linkage to obtain full pump directional control arm travel.
4. Start the engine and engage the drive pulley if necessary.
5. Bring the engine to maximum operating speed.
(This should not exceed 3600 rpm input speed on the PC, PL, PG, PE, PK and PJ Series Pumps)
(This should not exceed 3400 rpm input speed on the PR)
(This should not exceed 2800 rpm input speed when testing the PW)
Engine speed adjustment may be necessary to obtain 2800 rpm.
CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the
vehicles high pressure system lines. Failure to perform this properly could result in bodily injury.
6. With the directional control lever (on the vehicle) for the pump being tested, move the control arm in
full forward motion. (It may be necessary to lock the control arm into full forward position to prevent
false readings).
7. Operate without any load for approximately 30 seconds to 1 minutes. This allows the system oil tem-
perature to rise.
16 P Series
Note: Raising the system oil temperature will make a difference in the readings you receive. It has been
determined that to complete this test accurately, the oil temperature must be near system operating temperatures.
Suggested temperature range is 160- 210F (71.1 - 98.9C).
8. On the PC, PG, PE, PJ, PK, PL, PR and PW, tighten the flow meter restriction valve until the gauge reads 300
psi (21bar). Record the flow reading on the Bi-Directional Flow Meter.
9. Increase the pressure to 1100 PSI (76 bar) for all models (PC, PG, PJ, PK, PL, PR and PW). Record the flow
reading on the Bi-Directional Flow Meter.
10. The acceptable gpm flow droop or (difference) is:

PC 1.0 gpm (3.7 l/min)
PG/PL/PE 1.5 gpm (5.6 l/min)
PJ/PK 2.0 gpm (7.6 l/min)
PR 2.5 gpm (9.4 l/min)
PW 2.5 gpm (9.4 l/min)
If the difference exceeds these values the pump would not be operating efficiently and should be repaired or
replaced.
TEST EXAMPLE: PG/PL
300 psi (21 bar) reading 7 gpm (26 l/min) (1st reading)

1100 PSI (76 bar) reading 3 gpm (11 l/min) (2nd reading)
(PG/PL/PE)
300 psi (21 bar) reading 7 gpm (26 l/min) (1st reading)
1100 psi (76 bar) reading -3 gpm (11 l/min) (2nd reading)
4 gpm (15 l/min) (the difference)
Subtract the 1st reading from the 2nd.

(In this example, 4 gpm difference would
indicate further pump examination).
P Series 17
Section 4. Service and Maintenance
8. Inspect the vehicle control linkage to the
NOTE: Any servicing dealer attempting a
directional control arm on the P Series Pump.
warranty repair must have prior approval Also, insure the control arm is securely fastened
before conducting maintenance of a to the trunnion arm.
Hydro-Gear product, unless the servicing
dealer is a current authorized Hydro-Gear 9. Inspect the bypass on the P Series Pump to
Service Center. insure it is properly engaged for operation. If
the bypass is not fully engaged (rotated fully
clockwise) it will not function properly. For
External Maintenance vehicle movement without engine power, the
bypass may be backed out (2) turns maximum.
Regular external maintenance of a P Series Pump
This is only recommended for movement of
should include the following:
short distances at low speeds.
1. Check the vehicle operators manual for
the recommended load ratings. Insure the
current application does not exceed load Warning
rating.
Loosening the bypass will result in loss
2. Check fluid level in reservoir in accordance with of hydraulic braking capability.
vehicle manufacturers recommendations.
NOTE: After the oil has been drained Service and Maintenance
and maintenance has been performed, Procedures
clean oil should be poured directly into
the pump inlet and high pressure ports NOTE: Damage to P Series Pumps may
prior to plumbing connections and pump result from external or internal contami-
start-up. nation, heat from excess debris or lack
of lubrication and over-pressurization
3. Inspect the vehicle drive belt, idler pulley(s), and of the hydrostatic system. Follow guide-
idler spring(s). Insure that belt slippage is not
lines established in this manual and the
causing low input rpm to the pump.
vehicle manufacturers recommenda-
4. Inspect all external plumbing for possible leaks tions.
or loose fittings. An air leak may be difficult to
detect on the suction side or inlet line to the All the service procedures presented on the fol-
pump. Refer to Purging Procedures page 18. lowing pages can be performed while the P Series
Pump is mounted on the vehicle. Any servicing
5. Insure correct inlet filter(s) has been installed beyond those presented in this section must be
in accordance with the vehicle manufacturer performed after the pump has been removed from
recommendations. the vehicle.
6. Insure the reservoir is free of contaminants and Fluids

is properly vented.
The fluids used in Hydro-Gear products have been
7. Inspect the P Series Pump cooling fan (if carefully selected, and only equivalent, or better
applicable) for broken or distorted blades and products should be substituted.
remove any obstructions (grass clippings,
leaves or dirt). Inspect oil cooler (if applicable) Typically, an engine oil with a minimum rating of 55
for damaged fins and debris. SUS (9.0 cSt) at 230 F (110 C) maximum operat-
ing temperature and an API classification of SJ/CD
is allowed. Refer to the vehicle manufacturer for
recommended oil.
18 P Series
Fluid Volume and Level
WARNING
Certain situations may require additional fluid to
be added or even replaced. Refer to the vehicle
POTENTIAL FOR serious INJURY
manufacturers recommendations for the proper fill
location and level. After maintenance or oil change, Certain procedures require the vehicle
follow purging procedures below and check the engine to be operated and the vehicle to
fluid level once the unit has been operated for ap-
be raised off of the ground. To prevent
proximately 1 minute.
possible injury to the servicing techni-
FLUID CHANGE cian and/or bystanders, insure the ve-
hicle is properly secured.
In the event of oil contamination or degradation,
oil addition or change may alleviate certain per- 1. With the bypass valve open and the engine
formance problems. Refer to the vehicle manufac- running, slowly move the directional control
turers recommended oil change frequency. Refer to in both forward and reverse directions (5 to 6
purging procedures below after changing fluids. times). As air is purged from the unit, the oil level
in the reservoir will drop.
FILTERS
2. With the bypass valve closed and the engine
An inlet filter is required to insure that only clean fluid running, slowly move the directional control
enters the system. Refer to the vehicle manufacture in both forward and reverse directions (5 to
for approved filter replacement. 6 times). Check the oil level, and add oil as
required after stopping engine.
Purging Procedures
3. It may be necessary to repeat steps 1 and
Due to the effects air has on efficiency in hydrostatic 2 until all the air is completely purged from
drive applications, it is critical that air is removed or the system. When the P Series Pump moves
purged from the system. forward and reverse at normal speed and the
reservoir oil remains at a constant level, purging
These purge procedures must be preformed any- is complete.
time a hydrostatic system has been opened for
maintenance or repair, or if any additional oil has Cleanliness is a key factor in the successful repair of
been added to the system. pumps. Thoroughly clean all exposed surfaces prior
to any type of maintenance. Cleaning of all parts
Air creates inefficiency because it has compres- by using a solvent wash and air drying is usually
sion and expansion rates that are higher than that adequate. As with any precision equipment, all parts
of oil. must be kept free of foreign material and chemicals.
Protect all exposed sealing areas and open cavities
Air trapped in the oil may cause the following
from damage and foreign material.
symptoms:
Upon removal, all seals, O-rings, and gaskets
1. Noisy operation.
should be replaced. During installation, lightly lu-
2. Lack of power or drive after short-term bricate all seals, O-rings, and gaskets with clean
operation. petroleum jelly prior to assembly. Also protect the
inner diameter of seals by covering the shaft ma-
3. High operation temperature and excessive chined features with plastic wrap or equivalent.
expansion of oil.
Before starting, make sure the reservoir is at the

proper oil level. If it is not, fill to the vehicle manu-
facturers specifications.
The following procedures should be performed

with the vehicle drive wheels off the ground, then
repeated under normal operating conditions.
P Series 19
RETURN TO NEUTRAL SETTING
Warning WARNING
potential for serious injury Do not attempt any servicing or ad-
justments with the engine running.
Inattention to proper safety, operation, or Use extreme caution while inspecting
maintenance procedures could result in the drive belt assembly and all vehicle
personal injury, or damage to the equip- linkage!
ment. Before servicing or repairing the P
Series Pump, fully read and understand Follow all safety procedures outlined in
the safety precautions described in this the vehicle owners manual.
manual.
The return to neutral mechanism on the pump is 4. Check for axle rotation. If the axle does not
designed to set the directional control into a neutral rotate, go to Step 5. If the axle rotates, go to
position when the operator releases the vehicle Step 6.
hand control. Follow the procedures below to
properly adjust the return to neutral mechanism on 5. Stop the vehicles engine. Reattach and adjust
the pump: the vehicles linkage according to the vehicle
owners manual.
1. Confirm the pump is in the operating mode
(bypass disengaged). Raise the vehicles drive 6. Note the axle directional movement. Stop the ve-
tires off the ground to allow free rotation. hicle engine. Loosen the RTN adjustment screw
2. Remove the Original Equipment Manufacturers until the control arm can be rotated. Rotate the
(OEMs) control linkage at the control arm. control arm in the proper direction until neutral is
obtained (motor shaft does not rotate). Tighten
3. Start the engine and increase the throttle to full the RTN adjustment screw. Recheck according
engine speed. to steps 3 and 4. Refer to Figure 12.
RTN Adjusting Screw
Speed & Direction

Control Arm
Figure 17. P Series Pump RTN Adjustment
20 P Series
REPAIR - PC SERIES PUMP
Repair - PC Series Pump ..................................................................................................... 21-36
How to Use This Manual .............................................................................................................. 21
General Instructions .................................................................................................................... 21
Tools and Torques ....................................................................................................................... 22
Return to Neutral Linkage ............................................................................................................ 23
Standard Control Arm Linkage ..................................................................................................... 24
Fan Assembly .............................................................................................................................. 24
Input Shaft Seal ........................................................................................................................... 25
Trunnion Arm Seal ....................................................................................................................... 25
Shock Valves ............................................................................................................................... 26
Bypass ........................................................................................................................................ 26
Charge Pump-Standard or Thru Shaft......................................................................................... 27
Auxiliary Pump ............................................................................................................................. 28
End Cap ...................................................................................................................................... 29
Cylinder Block ............................................................................................................................. 30
Block Spring and Thrust Bearings ............................................................................................... 31
Swashplate and Cradle Bearings ................................................................................................ 31
Input Shaft ................................................................................................................................... 32
Trunnion Arm ............................................................................................................................... 33
Parts List ............................................................................................................................... 34-35
HOW TO USE THIS MANUAL

Each assembly is provided with an exploded view Lip-type seals (shaft seals) are used on the input
showing the parts involved. The item shaft and directional control shaft of each pump.
reference numbers in each illustration are for These seals can be replaced without major
assembly instructions only. See pages 34 and 35 disassembly of the unit. However, replacement of
for part names and descriptions. A these seals generally requires removal of the pump
complete exploded view and item list of the pump is from the machine. Upon removal, it is recommended
provided at the end of this section. that all seals, O-rings and gaskets be replaced.
GENERAL INSTRUCTIONS During installation, lightly lubricate all seals,

O-rings and gaskets with clean petroleum jelly prior
Cleanliness is a primary means of ensuring to assembly. Also protect the inner diameter of the
satisfactory life on repaired pumps. Thoroughly clean seals by covering the shaft with a cellophane (plastic
all exposed surfaces prior to any type of wrap, etc.) material.
maintenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with Parts requiring replacement must be replaced from
any precision equipment, all parts must be kept free the appropriate kits identified in the Items Listing,
of foreign material and chemicals. found at the end of this manual. Use only original
Hydro-Gear replacement parts found listed in BLN-
Protect all exposed sealing surfaces and open 51427 (CD).
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
PC Series 21
TOOLS AND TORQUES
Miscellaneous 3/8-Inch Drive Ratchet and Sockets

P Series Service & Repair Manual 7/16-inch Socket
Torque Wrench 1/2-Inch Socket
Scribe, Paint Pen, or Marker 11/16-Inch Socket
Seal Hook with a Magnet 10-mm Socket
Flat Blade Screwdriver Combination Wrenches
Pliers 7/16 Inch
Internal Snap Ring 1/2 Inch
Allen Wrenches 11/16 Inch
1/8 inch 10 mm
1/4 inch
Table 1. Required Tools
Item # and/or Description Torque
Case Drain (fitting torque) 200-250 lb-in (22.6-28.2 Nm)

System Port (fitting torque) 370-470 lb-in (41.8-53.1 Nm)
Inlet (fitting torque) 200-250 lb-in (22.6-28.2 Nm)
Fan Nut, Hex Lock 5/16-24 UNF 120-160 lb-in (13.5-18.1 Nm)
4, End Cap/Adapter Plate Bolts 180-220 lb-in (20.3-24.9 Nm)
10, Cap Screw 180-220 lb-in (20.3-24.9 Nm)
15, Bypass Valve 110-130 lb-in (12.4-14.7 Nm)
42A, 42B, Shock Valves/Check Plugs 180-240 lb-in (20.3-27.1 Nm)
44, System Charge Relief Kit (Aux Chg) 180-240 lb-in (20.3-27.1 Nm)
45, Aux Relief Valve Kit 180-240 lb-in (20.3-27.1 Nm)
56, Diagnostic Plug 84-120 lb-in (9.4-13.5 Nm)
66, Filter Cover Plug 55-85 lb-in (6.2-9.6 Nm)
67, Filter Cover 200-275 lb-in (22.6-31.1 Nm)
103, Screw 5/16 x .875 200-240 lb-in (22.6-27.1 Nm)
106, Nut, Hex Lock 5/16-24 UNF 180-220 lb-in (20.3-24.9 Nm)
164, Plug, Metal 7/16-20 84-120 lb-in (9.4-13.5 Nm)
Table 2. PC Pump Torque Values
22 PC Series
PC SERIES PUMP REPAIR
REMOVAL, INSPECTION AND/OR
REPLACEMENT OF RETURN TO
NEUTRAL ASSEMBLY
Refer to Figure 1. Inspection
Prior to disassembly, note the position of the scissor 1. With the arm control linkage removed, inspect
arm brackets and the tab on the outer control arm the trunnion arm (37) and trunnion arm seal (49).
bracket.
2. Inspect bushing (101) and all other linkage parts
Disassembly for damage, corrosion or wear.
CAUTION: The spring used on the return to neutral Assembly
linkage is under tension. To avoid possible injury,
use care and proper protection during disassembly 1. Install the inner return arm bracket, washer (104)
and assembly of the return to neutral linkage. and bolt (103).
1. Loosen (but do not remove) the nut (106). NOTE: Do not over tighten the bolt (103). The
bracket must move freely.
2. To relieve spring tension, carefully pry up on the
outer scissor control arm until it releases from 2. Install the outer control arm bracket, washer
the tab on the outer control arm bracket. (105) and bushing (101).
3. Remove the spring (102), nut (106) washer (104) 3. Install the inner scissor control arm bracket,
and outer scissor control arm bracket. washer (105), and outer scissor control arm
bracket.
4. Remove bushing (101), washer (105), and the
inner scissor control arm bracket. 4. Install washer (104), and nut (106). Tighten to
the correct torque value. See page 22.
5. Remove the outer control arm bracket, bolt
(103), washer (104) and the inner return arm 5. Install the spring (102).
bracket.
49
104
103
37 105
101
105
104
106
110
102
Figure 1. Return to Neutral Assembly
PC Series 23
REMOVAL, INSPECTION AND/OR REMOVAL, INSPECTION AND/OR
REPLACEMENT OF CONTROL ARM REPLACEMENT OF FAN ASSEMBLY
Refer to Figure 2. Refer to Figure 3.
Disassembly Disassembly
1. Remove the nut (106), washer (104) and bushing 1. Remove the fan shroud (210) from the mounting
(101). bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket.
2. Remove the nut (106) and fan assembly (90).
3. Remove bolt (103), washer (104) and the inner
control arm bracket. 3. Remove the bolts (10) and bracket (209).
Inspection Inspection
1. With the arm control linkage removed, inspect Inspect the fan shroud (210), fan assembly (90) and
the trunnion arm (37) and trunnion arm seal (49). mounting bracket (209) for damage.
2. Inspect bushing (101) and all other linkage parts Assembly
for damage, corrosion or wear.
1. To install the mounting bracket (209), align and
Assembly insert the bolts (10) into the bracket and charge
pump cover. While holding the charge cover in
1. Install the inner control arm bracket, washer place, tighten the bolts (10) per table 2, page
(104) and bolt (103). 22.
NOTE: Do not over tighten the bolt (103). The 2. Install the fan and washer assembly onto the
bracket must move freely. shaft.
2. Install the outer control arm bracket, bushing 3. Install the nut (106) and tighten per table 2, page
(101), washer (104) and nut (106). Tighten to 22.
4. Install the fan shroud (210) onto the mounting
bracket (209). Make sure that all shroud lock
tabs are fully engaged in the mounting bracket
slots.
209
49 (2X) 10
104
103
90
104
37
106
101
106
110
210
Figure 2. Standard Control Arm
Figure 3. Fan Assembly

24 PC Series
REPLACEMENT OF INPUT SHAFT REPLACEMENT OF TRUNNION ARM
SEAL SEAL
1. Remove retaining ring (22) from housing. 1. Remove the RTN assembly or control arm.
2. Remove lip seal (20). Care must be taken to 2. Remove the retainer and lip seal (49) from the
prevent damage to the housing bore, shaft housing. Care must be taken to prevent damage
sealing surface, or bearing. Once removed, the to the housing trunnion bore, trunnion arm and
seal is not reusable. sealing surface. Once removed the retainer and
lip seal are not reusable.
Inspection
Inspection
With seal removed inspect the spacer (21) and
housing (1) bore for damage, corrosion or wear. With the lip seal (49) removed, inspect the area for
corrosion and wear. Inspect the trunnion bore area
Assembly sealing surface for damage or wear.
1. Lubricate the new lip seal (20) inside diameter Assembly
with petroleum jelly.
1. Lubricate the new lip seal (49) inside diameter
2. Wrap the input shaft (18) with plastic wrap to with petroleum jelly.
prevent damage to the inner surface of the lip
seal (20). 2. Wrap the trunnion arm with plastic wrap to
prevent damage to the inner surface of the lip
3. Slide spacer (21) and seal (20) over shaft (18) seal (49).
so that lettering on the seal faces out.
3. Slide the lip seal (49) over the trunnion arm so that
4. Press the lip seal (20) into the housing bore. the lettering on the seal (49) faces out.
Insure the lip seal (20), shaft (18) or housing (1)
bore do not become damaged. Remove the 4. Press the lip seal (49) into the housing bore.
plastic wrap. Insure the seal (49), trunnion arm, and housing
bore do not become damaged. Remove plastic
5. Install the retaining ring (22) into the housing (1) wrap.
bore groove. Refer to Figure 4.
5. Install the retainer from (49) over the trunnion
arm on top of the lip seal. Press into the trunnion
seal bore in the housing until the retainer mates
against the trunnion seal.
6. Install the RTN assembly or control arm.
Figure 4. PC Pump Input Shaft Seal
Figure 5. Trunnion Arm Seal

PC Series 25
REPLACEMENT OF SHOCK VALVES REPLACEMENT OF THE BYPASS
Perform disassembly, inspection and assembly on Disassembly
shock valve one side at a time. Some units vary in
A side to B side configuration. 1. Loosen the bypass valve (15) using a 7/16-inch
wrench.
Disassembly
2. Remove the bypass (15) from the end cap.
1. Remove the shock valve (42) with an 11/16-inch
wrench. Inspection
2. Remove the shock valve spring and the shock 1. Inspect the bypass O-rings and mating seats in
valve from the end cap. the end cap for damage or foreign material.
Inspection 2. If damaged or worn, replace bypass (15).
Inspect the shock valve (42) and mating seat in the Assembly
end cap for damage or foreign material.
1. Position the pump so the bypass port is
Assembly horizontal.
1. Position the pump so the shock valve port is 2. Insert the bypass (15) into the bypass port of
horizontal. the end cap. Tighten to the correct torque value.
See Table 2, page 22 (Torque Values).
2. Insert the shock valve spring and shock valve
as one assembly into the check plug port. Tighten
to the correct torque value. See Table 2, page
22 (Torque Values).
3. Repeat disassembly, inspection and assembly

for the opposite port.
Figure 7. PC Pump Bypass
Figure 6. PC Pump Shock Valves
26 PC Series
REMOVAL, INSPECTION AND NOTE: For thru shaft charge pump assembly,
ASSEMBLY OF THE STANDARD OR follow steps 1 thru 8. For standard charge pump,
follow steps 3 thru 8.
THRU SHAFT CHARGE PUMP
Refer to Figure 8. Assembly
Disassembly 1. Lubricate the new shaft seal with petroleum jelly.
1. Prior to removal of the charge pump cover, place 2. Press the shaft seal into the charge cover. Be
a mark on the cover and end cap for alignment careful not to damage the shaft seal or charge
at assembly. cover bore.
2. Using a 1/2-inch wrench, loosen the charge 3. Position the pump with the input shaft down, and
pump cover bolts (10) from the end cap (2). While the end cap (2) horizontal. Place the charge ball
holding the charge cover (6) in place, remove (44) in the end cap (2) charge passage so the
the charge cover bolts (10). ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
3. Remove the charge cover, O-ring (8) and ball.
gerotor items (7). Carefully check for and remove
the charge spring and charge ball (44). 4. Insert the inner gerotor over input shaft (18).
4. For thru shaft charge pump, remove the shaft 5. Align the outer gerotor to fit over the inner gerotor.
seal. 6. Insert the O-ring (8) into the groove in the charge
Inspection cover.
1. Inspect the charge cover O-ring (8) and running 7. Position the charge cover and O-ring with the
surfaces for damage. Inspect the spring, check aligning mark on the end cap. Place the charge
ball (44), and mating seat in the end cap (2) for cover and O-ring as one piece over the charge
damage or foreign material. spring and gerotor assembly. Insure the spring
fits into the charge cover spring retaining groove.
2. Inspect the charge cover bore for damage
corrosion or wear. 8. Align and insert the charge pump cover bolts
(10) into the end cap (2). Tighten to the correct
NOTE: If the end cap (2) is to be removed from the torque value. See Table 2, page 22 (Torque
housing, do not assemble the charge pump (6)
Values).
until the end cap is installed on the housing.
8
44
7
THRU SHAFT
6
18
8
(2X) 10
7
STANDARD
6
(2X) 10
Figure 8. PC Pump Standard or Thru Shaft Charge Pump
PC Series 27
REMOVAL, INSPECTION AND/OR 3. Inspect the filter cover assembly threads and
filter for wear, damage or foreign material.
REPLACEMENT OF AUXILIARY
PUMP (IF EQUIPPED) Assembly
Refer to Figure 9. 1. Install the check ball, spring, and cap as one
assembly (45) into the auxiliary relief valve port.
Disassembly Tighten to the correct torque value. See page
22.
1. Prior to removal of the auxiliary pump, place a
mark on the auxiliary pump (6), charge pump 2. Install the poppet, spring and cap as one
(7) and end cap (2) for alignment at assembly. assembly (44) into the charge relief port.
Tighten to the correct torque value. See page
2. Use a 10 mm wrench to loosen the auxiliary 22.
pump bolts (10) from the end cap (2). While
holding the auxiliary pump in place, remove the 3. Install the filter (54) and O-ring into the filter
bolts (10). cover assembly (67). Install the assembly (67)
into the auxiliary pump and tighten. Install plug
3. Remove the auxiliary pump, gasket, O-ring (8) (66) into the filter cover (67).
and charge pump (7). While removing the
charge pump, be sure to retain the spring and 4. Lay the PC pump (input shaft down), so the
ball (44A) housed in the end cap (2). end cap is horizontal. Install the O-ring (8) into
the charge pump (7).
4. Remove the plug (66) from the filter cover (67).
5. Install the gasket onto the auxiliary pump.
5. Use a 7/8 inch wrench to remove the filter cover
assembly (67) from the pump. 6. Make sure that the ball and spring (44A) are
seated in the end cap (2), then position the
6. Remove the O-ring and filter (54). auxiliary pump and gasket with the aligning mark
on the charge pump (7). Insure that the pump
7. Remove the charge relief valve assembly (44)
fully engages the alignment pins (69).
and auxiliary relief valve assembly (45) from the
auxiliary pump. 7. Align and insert the bolts (10) into the auxiliary
pump. While holding the auxiliary pump and
Inspection
charge pump in place, tighten the bolts (10)
1. With the auxiliary pump removed, inspect the per table, page 22.
pump running surfaces for wear or damage.
2. Inspect all O-rings, gasket and mounting seats.
44A
18
7 (2X) 69
44
8 2
67 45
54 164
66
(2X) 10
Figure 9. PC Series Auxiliary Pump
28 PC Series
REMOVAL, INSPECTION AND 3. Replace the housing gasket (5) with a new
gasket before assembly.
ASSEMBLY OF THE END CAP
Assembly
Refer to Figure 10.
1. Install housing gasket (5) into housing gasket
Disassembly seat of housing (1).
1. Remove charge pump. (See page 27). 2. Lubricate the mating surface of the cylinder
block (31) to end cap (2) with clean oil prior to
2. Using a 10 mm wrench, loosen the end cap bolts installation.
(4) evenly.
3. Install end cap (2). Before installing the four
3. Hold the end cap (2) in place and remove the end cap bolts (4), push down on end cap (2)
four end cap bolts (4). verifying alignment and insuring that the
cylinder block pistons spring back and forth.
4. Slowly remove the end cap (2). Install end cap bolts (4). Tighten to the correct
5. Remove housing gasket (5). torque value. See Table 2, page 22 (Torque
Values)
Inspection
4. Install the charge pump. (See page 27).
1. Inspect the end cap (2) body for damage, nicks
or unusual wear patterns. Replace if necessary.
2. Inspect the running surface (side that contacts

the cylinder block) (31). The running surface
may show evidence of minor abrasive rings, this
is normal.
Grooving in the plate, or material transfer that is

evident when the surface is checked by dragging
a fingernail across it, would be cause for
replacement of the end cap (2).
31
1
5
2
Figure 10. PC Pump End Cap
PC Series 29
REMOVAL, INSPECTION AND 2. Install piston seats into the end of the pistons.
ASSEMBLY OF THE CYLINDER 3. Install springs into the pistons.
BLOCK
4. Install each piston, spring and seat assembly into
the cylinder block.
Refer to Figure 11.
NOTE: To assist in cylinder block in-
Disassembly
stallation, a rubber band can be placed
1. Remove charge pump. (See page 27). around all of the pistons to hold them
in position.
2. Remove end cap. (See page 29).
After the cylinder block is installed, cut
3. Tilt the pump on its side and drain remaining oil.
the rubber band and remove it from the
Lift out the cylinder block assembly (25).
housing.
4. Remove the pistons, springs and piston seats.
5. With the pump housing tilted on its side, install
Inspection the cylinder block assembly (25) with pistons
contacting the thrust bearing.
1. Inspect the running surface of the cylinder block
and piston ends for damage, nicks or unusual
wear patterns. The running surface may show NOTE: To check if the cylinder block
evidence of minor abrasion. This will be normal assembly is installed correctly, position
wear. If grooved or smeared, replace with a new the pump housing vertically and sup-
cylinder block assembly. port the housing at the mounting flange.
2. Inspect the piston springs for distortion or breaks. Push down on the cylinder block. The
If necessary, replace with a new cylinder block cylinder block must move up and down
kit. freely. If it does not, remove the cylin-
der block assembly and reinstall.
3. Inspect the piston seats. Residual oil may cause
these to remain stuck to the inside of the pistons.
6. Install the end cap. (See page 29).
Assembly
7. Install the charge pump. (See page 27).
1. Apply a thin layer of clean oil to the pistons and
springs.
Figure 11. PC Pump Cylinder Block Assembly
30 PC Series
REMOVAL, INSPECTION AND REMOVAL, INSPECTION AND
ASSEMBLY OF BLOCK SPRING AND ASSEMBLY OF SWASHPLATE AND
THRUST BEARING CRADLE BEARINGS
1. Remove the block spring (29). Remove the swashplate (32).
2. Remove the thrust bearing and races (34). Inspection
Inspection 1. Inspect the running surface of the bearing pocket

of swashplate (32) for damage, nicks or unusual
1. Inspect and replace the block spring (29) if it is wear patterns. The running surface may show
distorted or broken. evidence of minor abrasion. This is normal wear.
Inspect the cradle bearing side of the swashplate
2. Inspect the running surface of the bearing races (32) for damage. Replace if necessary.
for damage, nicks or unusual wear patterns. The
running surface may show evidence of minor 2. Inspect the cradle bearings attached to the inside
abrasion. This will be normal wear. of the housing (1) for normal wear patterns and
placement, and insure they are staked securely
Inspect the bearings for free movement. Inspect in place. If the bearings are damaged, replace
the bearing cage for distortion or damage. housing (1).
Replace if necessary.
NOTE: The cradle bearings will have dis-
Assembly
coloration due to normal wear. Under
1. Install thrust bearing and race assembly normal circumstances, this will not war-
(34). rant replacement.
2. Install block spring (29). Assembly
1. Install swashplate (32) by holding trunnion arms

slot guide (38) with a flat tip screwdriver. Use
the screwdriver to hold the slot guide in place
while positioning the swashplate (32) onto the
cradle bearing in the housing (1).
2. Rotate trunnion arm (37) to verify that the

swashplate moves freely.
Figure 12. PC Pump Block Spring and

Thrust Bearing
Figure 13. PC Pump Swashplate and

Cradle Bearings
PC Series 31
REMOVAL, INSPECTION AND Assembly
ASSEMBLY OF INPUT SHAFT NOTE: If trunnion arm is to be removed,
do not assemble input shaft until the trun-
Refer to Figure 14.
nion arm is installed.
Disassembly
NOTE: During installation, lightly lubri-
1. Remove the retaining ring (22).
cate all seals, O-rings and gaskets with
2. Remove the lip seal (20). clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
3. Remove the spacer (21). by covering the shaft with plastic wrap.
3. Remove the shaft (18) and bearing (19) assembly
(18) from the pump. 1. If removed, press bearing (19) onto shaft (18)
tight against the shoulder of the shaft. Install
Inspection retaining ring (23) onto the shaft (18).
1. Inspect the input shaft (18) for worn splines, 2. Install input shaft assembly (18) into the housing
surface damage, or keyway damage. Replace (1) bore. Light tapping with a rubber mallet may
shaft assembly if necessary. be necessary on the input shaft (18) once the
bearing is aligned with the housing (1) bore.
2. Inspect the bearing (19) for evidence of scoring, Verify that the shaft rotates smoothly.
corrosion, or damage. If the bearing must be
replaced, remove the retaining ring (23) and use 3. Install spacer (21).
a press or bearing puller to remove the bearing.
4. Install new lip seal (20) with the flat side of the
3. Inspect and replace the spacer (21) if it is bent seal toward the outside of the pump.
or broken.
5. Remove the plastic wrap.
4. Inspect and replace the retaining ring (22) if it is
bent or broken. 6. Install retaining ring (22).
NOTE: Upon removal, all seals, O-rings

and gaskets should be replaced.
Figure 14. PC Pump Input Shaft
32 PC Series
INSTALLATION OF TRUNNION ARM 1. Install the trunnion arm (37) into the housing (1)
bore. Rotate the trunnion arm to verify free
Refer to Figure 15. movement.
Disassembly NOTE: During installation, lightly lubri-
1. Remove the slot guide (38). cate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
2. Remove and discard the trunnion seal retainer Also protect the inner diameter of the
and seal (49). seals by covering the shaft with plastic
3. Remove the trunnion arm (37). wrap. Remove the plastic wrap after the
seal is installed.
Inspection
NOTE: Upon removal, all seals, O-rings 2. Install a new seal and seal retainer (49).
and gaskets should be replaced. 3. Install slot guide (38).
1. Inspect the trunnion arm (37) for wear or 4. To completely assemble the pump, refer to the
damage. Replace the trunnion arm if necessary. assembly steps on pages 23-33. Begin with the
trunnion arm assembly steps listed on page 33
2. Check for excessive play between trunnion arm and complete the assembly steps in reverse
(37) and housing (1). Replace housing if order working toward the front of the manual.
necessary.
38
49
37
Figure 15. PC Pump Trunnion Arm
PC Series 33
34
Figure 16. PC Pump
Kit Number
BOXES INDICATE ITEMS INCLUDED IN KITS.
PC Series
ITEM LIST - PC SERIES
Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers.
No. Description No. Description
1 Housing Kit 44 Charge Relief Valve Kit (1/4 in. Plastic

2 End Cap Ball and 50654 Spring)
4 Screw, Hex Flange, M8 x 1.25 45 Auxiliary Relief Valve Kit
5 Housing O-Ring 49 Trunnion Seal/Retainer Kit
6 Charge Pump Kit (Std. Charge) 54 Filter Kit
Charge Pump Kit (Std. Charge) Thru 55 Plate, Adapter (Gear AA)
Shaft 56 Plug, 5/16 - 24
7 STD Gerotor Assy (0.11 cu in./rev) 66 Plug
8 O-Ring 67 Filter Cover
10 Cap Screw, Hex, 5/16 - 18 x 1.0 69 Pin, Straight Headless
15 Bypass Valve Kit (No Bleed Orifice) 80 Pin, Straight Headless
18 Pump Shaft Kit (1/2 in. Keyed w/Std. 90 Fan Kit
Charge) 100 Overhaul Seal Kit
Pump Shaft Kit (1/2 in. Keyed, Thru 101 Spacer, Return
Shaft w Std. Charge 102 Spring, Extension
Pump Shaft Kit (9 tooth w/Std. Charge) 103 Screw, 5/16 x 0.875 in. (PATCH)
19 Ball Bearing, 17 x 40 x 12 mm 104 Washer, 0.34 x 0.88 x 0.06 in.
20 Lip Seal, 17 x 40 x 7 PTC 105 Washer, Nylon
21 Spacer 106 Nut, Hex Lock, 5/16 - 24 UNF
22 Retaining Ring 110 Return-to-Neutral Kit, Std.
23 Retaining Ring Return-to-Neutral Kit, CW Scissor
25 Cylinder Block Kit Return-to-Neutral Kit, CCC Scissor
29 Block Spring Return-to-Neutral Kit,
32 Swashplate 209 Shroud Bracket
34 Ball Thrust Bearing 210 Shroud
37 Trunnion Arm, Tapered Square
Trunnion
Arm, Double D
38 Slot Guide
42 Shock Valve Kit
2900 psi, (200 bar), No Orifice
2900 psi, (200 bar), 0.024 in. Orifice
PC Series 35
36 PC Series
REPAIR - PG and PE SERIES PUMP
Repair - PG and PE Series Pump.......................................................................................... 37-54
How to Use This Manual..............................................................................................................37
General Instructions.....................................................................................................................37
Tools and Torques........................................................................................................................38
Return to Neutral Linkage.............................................................................................................39
Standard Control Arm Linkage.....................................................................................................40
Fan Assembly...............................................................................................................................40
Input Shaft Seal............................................................................................................................41
Trunnion Arm Seal........................................................................................................................41
Check Valves................................................................................................................................42
Shock Valves................................................................................................................................42
Bypass..........................................................................................................................................43
Charge Pump-Standard or Thru Shaft..........................................................................................44
Auxiliary Pump..............................................................................................................................45
End Cap........................................................................................................................................46
Cylinder Block...............................................................................................................................47
Block Spring and Thrust Bearings................................................................................................48
Swashplate and Cradle Bearings.................................................................................................48
Input Shaft....................................................................................................................................49
Trunnion Arm................................................................................................................................50
Parts List................................................................................................................................. 52-53

Each assembly is provided with an exploded Lip-type seals (shaft seals) are used on the input
view showing the parts involved. The item shaft and directional control shaft of each pump.
reference numbers in each illustration are for These seals can be replaced without major disas-
assembly instructions only. See pages 52 and sembly of the unit. However, replacement of these
53 for part names and descriptions. A complete seals generally requires removal of the pump from
exploded view and item list of the pump is provided the machine. Upon removal, it is recommended that
at the end of this section. all seals, O-rings and gaskets be replaced.

satisfactory life on repaired pumps. Thoroughly seals by covering the shaft with a cellophane (plastic
clean all exposed surfaces prior to any type of main- wrap, etc.) material.
tenance. Cleaning of all parts by using a solvent
wash and air drying is usually adequate. As with any Parts requiring replacement must be replaced from
precision equipment, all parts must be kept free of the appropriate kits identified in the Items Listing,
foreign material and chemicals. found at the end of this manual. Use only original
PG / PE Series 37
TOOLS AND TORQUES

Torque Wrench 9/16-inch Socket
Scribe, Paint Pen, or Marker 5/8-inch Socket
Flat Blade Screwdriver
Combination Wrenches
Pliers 1/2 inch
Internal Snap Ring 9/16 inch
5/8 inch
Allen Wrenches 7/8 inch
5mm 10 mm
3/16 inch
1/4 inch

4, End Cap Bolts 180-220 lb-in (20.3-24.9 Nm)
10, Cap Screw (Aux Pump and Shroud Bracket) 180-220 lb-in (20.3-24.9 Nm)
10, Cap Screw (Charge Pump Cover) 87-118 lb-in (9.8-13.3 Nm)
95, Screw, Socket Head Set 100-185 lb-in (11.3-20.9 Nm)
103, Screw 5/16 x .875 200-240 lb-in (22.6-27.1 Nm)
106, Bolt 180-220 lb-in (20.3-24.9 Nm)
107, Nut, Hex Lock 5/16-24UNF 180-220 lb-in (20.3-24.9 Nm)
Table 2. PG / PE Pump Torque Values
38 PG / PE Series
PG and PE SERIES PUMP REPAIR
NEUTRAL ASSEMBLY
Prior to disassembly, note the position of the scis- 1. With the arm control linkage removed, inspect
sor arm brackets and the tab on the outer control the trunnion arm (37) and trunnion arm seal
arm bracket. (49).
Disassembly 2. Inspect scissor arm (99) and all other linkage
CAUTION: The spring used on the return to neutral parts for damage, corrosion or wear.
linkage is under tension. To avoid possible injury, Assembly
use care and proper protection during disassembly
and assembly of the return to neutral linkage. 1. Install the inner return arm bracket(98), washer
(104) and bolt (103).
1. Loosen (but do not remove) the bolt (106)/
nut(107). NOTE: Do not over tighten the bolt (103). The
outer scissor control arm until it releases from 2. Install the inner scissor control arm(94)
the tab on the outer control arm bracket.
3. Tighten washer (104), and nut (103) to the
3. Remove the spring (102), bolt (106)/nut (107) correct torque value. See page 38.
and washer (104).
4. Install the scissor arm(99).
4. Remove the scissor arm (99).
5. Install washer(104) and bolt (106)/nut(107) to
5. Remove the outer control arm bracket(94), bolt the correct torque value. See page 38.
(103), washer (104) and the inner return arm
bracket(98). 5. Install the spring (102).
Prior to serial # 8001PXXXXX
104
107
After serial # 8001PXXXXX
Figure 1. PG / PE Pump Return to Neutral
PG / PE Series 39
1. Remove the bolt (106), washer (104) and 1. Remove the fan shroud (210) from the mounting
bushing (101). bracket (209) by carefully pushing down on the
shroud tabs.
the trunnion arm (37) and trunnion arm seal mounting bracket (209) for damage.
(49).
Assembly
for damage, corrosion or wear. 1. To install the mounting bracket (209), align and
insert the bolts (10) into the bracket and charge
Assembly pump cover. While holding the charge cover in
place, tighten the bolts (10) per table 2, page
1. Install the inner control arm bracket, washer
38.
(104) and bolt (103).
2. Install the fan and washer assembly onto the
NOTE: Do not over tighten the bolt (103). The
shaft.
3. Install the nut (106) and tighten per table 2, page
2. Install the outer control arm bracket, bushing
38.
(101), washer (104, and bolt (106). Tighten to
the correct torque value. See page 38. 4. Install the fan shroud (210) onto the mounting
slots.
Prior to serial # 8001PXXXX
209
104
107
(2X) 10
90
Figure 2. PG / PE Pump Standard Control Arm
106
210
Figure 3. PG / PE Pump Fan Assembly

40 PG / PE Series
REPLACEMENT OF INPUT SHAFT REPLACEMENT OF TRUNNION
SEAL ARM (CONTROL ARM) SEAL
1. Remove retaining ring (22) from housing. 1. Remove the retainer and lip seal (49) from the
housing (1). Care must be taken to prevent
2. Remove lip seal (20). Care must be taken to damage to the housing trunnion bore, trunnion
prevent damage to the housing bore, shaft arm (37) and sealing surface. Once removed
sealing surface, or bearing. Once removed, the the retainer and lip seal is not reusable.
seal is not reusable.
Inspection
Inspection
1. With the lip seal (49) removed, inspect the area
1. With seal removed inspect the spacer (21), for corrosion and wear. Inspect the trunnion bore
input shaft bearing (19) and housing (1) bore area sealing surface for damage or wear.
Assembly
Assembly
1. Lubricate the new lip seal (49) with petroleum
1. Lubricate the new lip seal (20) inside diameter jelly.
2. Wrap the trunnion arm (37) with plastic wrap to
2. Wrap the input shaft (18) with plastic wrap to prevent damage to the inner surface of the lip
prevent damage to the inner surface of the lip seal (49).
seal (20).
3. Slide the lip seal (49) over the trunnion arm (37)
3. Slide seal (20) over shaft (18) so that lettering so that the lettering on the seal (49) faces out.
on the seal faces out.
4. Press the lip seal (49) into the housing bore
4. Press the lip seal (20) into the housing bore. (1). Insure the seal (49), trunnion arm (37), and
Insure the lip seal (20), shaft (18) or housing (1) housing bore do not become damaged. Remove
bore do not become damaged. Remove plastic the plastic wrap.
wrap.
5. Install the retaining ring (22) into the housing (1) arm (37) on top of the lip seal (49). Press into
bore groove. the trunnion seal bore in the housing until the
retainer mates against the trunnion seal.
22
20
21
19
18
1
37
Figure 4. PG / PE Pump Input Shaft Seal 49
Figure 5. PG / PE Pump Trunnion Arm Seal

PG / PE Series 41
REMOVAL, INSPECTION AND/OR REMOVAL, INSPECTION AND/
REPLACEMENT OF CHECK VALVES OR REPLACEMENT OF SYSTEM
Refer to Figure 6.
CHECK RELIEFS (SCRS) OR
SHOCK VALVES
Disassembly
Refer to Figure 7.
Perform disassembly, inspection and assembly on
check valves one side at a time. Some units vary
Disassembly
in A side to B side check configuration.
1. Remove the check valve (42) with an 1/4 allen
SCR/shock valve one side at a time. Some units
wrench.
vary in A side to B side configuration.
2. Remove the valve spring and poppet from the
1. Remove the SCR (42) with a 7/8 wrench or the
end cap (2).
shock valve (42) with an 11/16 wrench.
Inspection
2. Remove the check relief/shock valve spring and
1. Inspect the poppets and mating seats in the end the check relief/shock valve from the end cap
cap (2) for damage or foreign material. (2).
Assembly Inspection
1. Lay the pump on its side, so the check plug port 1. Inspect the check relief or shock valve (42) and
is horizontal. mating seat in the end cap (2) for damage or
foreign material.
2. Insert the check plug, spring and poppet (42) as
one assembly into the check plug port. Tighten, Assembly
reference Table 2, page 38 for torque values.
1. Lay the pump on its side, so the check plug port
3. Repeat disassembly, inspection and assembly is horizontal.
for the opposite port side.
2. Insert the system check relief spring and check
relief or shock valve spring and shock valve as
one assembly into the check plug port. Tighten
to the correct torque value. See page 38.
42A
(PORT A 3. Repeat disassembly, inspection and assembly
SIDE)
2
42B
(PORT B
SIDE)
42A
Figure 6. PG / PE Pump Check Valves
42B
2/25
Figure 7. PG / PE Pump Shock Valves
42 PG / PE Series
REMOVAL, INSPECTION AND /OR
REPLACEMENT OF THE BYPASS
Refer to Figure 8.
Disassembly
1. Loosen the bypass valve (15) using a 5/8

wrench.
2. Remove the bypass (15) from the end cap (2).
Inspection
1. Inspect the bypass O-rings and mating seats

in the end cap (2) for damage or foreign
materials.
2. If damaged or worn replace bypass (15)
Assembly
1. Lay the pump on its side, so the bypass port is

horizontal.
2. Insert the bypass (15) into the bypass port on

the end cap (2). Tighten to the proper torque
value. See page 38.
15
Figure 8. PG / PE Pump Bypass
PG / PE Series 43
ASSEMBLY OF STANDARD OR NOTE: For the Thru Shaft charge pump
THRU SHAFT CHARGE PUMP follow steps 1-8. For the Standard charge
pump follow steps 3-8.
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum
Disassembly jelly.
a mark on the cover and end cap for alignment careful not to damage the seal or charge cover
at assembly. bore.
2. Using a 1/2 inch wrench, or 5 mm allen wrench, 3. Position the pump with the input shaft down, and
loosen the charge pump cover bolts (10) from the end cap (2) horizontal. Place the charge ball
the end cap (2). While holding the charge cover (44) in the end cap (2) charge passage so the
in place, remove the charge cover bolts (10). ball mates to the end cap (2) charge ball seat.
Place the charge spring, on top of the charge
3. Remove the charge cover, O-ring and gerotor ball.
items (6). Carefully check for and remove the
charge spring and charge ball (44). 4. Insert the inner gerotor over input shaft (18).
4. For the Thru Shaft charge pump, remove the 5. Align the outer gerotor to fit over the inner
shaft seal. gerotor.
Inspection 6. Insert the O-ring into the groove in the charge
cover.
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check 7. Position the charge cover and O-ring with the
ball (44), and mating seat in the end cap (2) for aligning mark on the end cap. Place the charge
damage or foreign material. cover and O-ring with aligning mark on the end
cap. Place the charge cover and O-ring as
NOTE: If the end cap (2) is to be re-
one piece over the charge spring and gerotor
moved from the housing, do not as- assembly. Insure the spring fits into the charge
semble the charge pump (6) until the cover spring retaining groove.
end cap is installed on the housing.
8. Align and insert the charge pump cover bolts
2. Inspect the charge cover bore for damage, (10) into the end cap (2). Tighten to the correct
corrosion or wear. torque value. See Table 2, page 38. (Torque
Values.)
THRU SHAFT 44
6
18
(2X) 10
STANDARD
(2X) 10
Figure 9. PG / PE Pump Standard or Thru Shaft Charge Pump
44 PG / PE Series
Disassembly assembly (45) into the auxiliary relief valve port.
38.
mark on the auxiliary pump, charge pump (7)
and end cap (2) for alignment at assembly. 2. Install the plug (56). Tighten to the correct torque
value. See page 38.
2. Use a 10mm wrench to loosen the auxiliary
pump bolts (10) from the end cap (2). While 3. Install the poppet, spring and cap as one
holding the auxiliary pump in place, remove the assembly into the charge relief port. Tighten to
bolts (10). the correct torque value. See page 42.
3. Remove the auxiliary pump, gasket (75), O-ring 4. Install the filter (54) and O-ring onto the filter
(59) and charge pump (7). While removing the cover assembly (67). Install the assembly (67)
charge pump, be sure to retain the spring and into the auxiliary pump and tighten. Install plug
ball (44A) housed in the end cap (2). (66) into the filter cover (67).
4. Remove the plug (66) from the filter cover 5. Lay the PG pump (input shaft down), so the end
(67). cap is horizontal. Install the O-ring (59) into the
charge pump (7).
assembly (67) from the auxiliary pump. 6. Install the gasket (75) onto the auxiliary pump.
6. Remove the O-ring and filter (54). 7. Make sure that the ball and spring (44A) are
7. Remove the charge relief valve assembly (44),
auxiliary pump and gasket with the aligning mark
plug (56) and auxiliary relief valve assembly (45)
from the auxiliary pump.
fully engages the alignment pins (69).
Inspection
8. Align and insert the bolts (10) into the auxiliary
1. With the auxiliary pump removed, inspect the pump. While holding the auxiliary pump and
pump running surfaces for wear or damage. charge pump in place, tighten the bolts (10) per
table 2, page 38.
2. Inspect all O-rings, gasket and mounting
seats.
44A
69
7
6
59
64 75
59 2
44
45
10
54 56
64
66
67 64
10
Figure 10. PG / PE Series Auxiliary Pump

PG / PE Series 45
REMOVAL, INSPECTION AND NOTE: Grooving in the valve plate and or
end cap, made evident when the surface is
ASSEMBLY OF THE END CAP AND checked by dragging a fingernail across it,
VALVE PLATE would be cause for replacement of the valve
Refer to Figure 11a and 11b. plate.
3. Inspect and replace alignment pins (3) if bent

Disassembly or distorted.
1. Using a 10 mm wrench, loosen the end cap bolts 4. Replace the housing gasket (5) with a new
(4) evenly. gasket before reassembly.
2. Keeping the end cap (2) held in place, remove Assembly
the four end cap bolts (4).
1. Install housing gasket (5) into housing gasket
3. Slowly remove the end cap (2). seat of housing (1).
4. Remove the valve plate (31). 2. Install alignment pins (3) into housing (1).
NOTE: Not applicable in PE-series pumps. 3. Lubricate the valve plate prior to installation.
5. Remove housing alignment pins (3). Install valve plate (31) so the stamped letters
UP on the valve plate are facing up toward
6. Remove housing gasket (5). the end cap.
Inspection NOTE: Not applicable in PE-series pumps.
1. Inspect the end cap body (2) for damage, 4. Lubricate the end cap (2) face prior to
nicks or unusual wear patterns. Replace if installation in PE-series pumps.
necessary.
5. Install end cap (2). Before installing the four
2. Inspect the running surface (side that contacts end cap bolts (4), push down on the end cap
the cylinder block) of the valve plate (31). The (2) verifying alignment and insuring that the
running surface may show evidence of minor cylinder block pistons spring back and forth.
abrasive rings, this is normal. Install end cap bolts (4). Tighten, reference
Table 2, page 38 torque values.
PG Series Pumps (With Valve Plate) PE Series Pumps (No Valve Plate)
1
31
5 5
2 2
4 4
Figure 11a. PG Pump End Cap Figure 11b. PE Pump End Cap
46 PG / PE Series
Assembly
REMOVAL, INSPECTION AND
ASSEMBLY OF THE CYLINDER 1. Install piston seats into the end of the pistons.
BLOCK 2. Install springs into the pistons.
Refer to Figure 12.
3. Install one at a time, pistons, springs and seats
Disassembly as one assembly into the cylinder block.
1. Tilt the pump on its side, drain remaining oil. Lift 4. With the pump housing tilted on its side, install
out the cylinder block assembly (25). the cylinder block assembly (25) with pistons
contacting the thrust bearing.
Inspection NOTE: To check that piston placement is

1. Inspect the running surface of the cylinder block correct, push downward on the cylinder
and piston ends for damage, nicks or unusual block assembly (25). If this results in a
wear patterns. The running surface may show spring action the block assembly has
evidence of minor abrasion. This will be normal been installed correctly. If this cannot be
wear. If grooved or smeared, replace with a new accomplished, remove and reassemble
cylinder block assembly. the block assembly. Place a rubber band
around the cylinder block pistons to hold
2. Inspect the piston springs for distortion or
breaks. If necessary, replace with a new cylinder them in position during installation. Then
block kit. after installation cut the rubber band and
remove it. Check cylinder block assem-
3. Inspect the piston seats. Residual oil may bly for spring action.
cause these to remain stuck to the inside of the
pistons.
25
Figure 12. PG / PE Pump Cylinder Block
PG / PE Series 47
REMOVAL, INSPECTION AND REMOVAL, INSPECTION OF
ASSEMBLY OF BLOCK SPRING, SWASHPLATE, INSPECTION OF
THRUST WASHER, AND THRUST CRADLE BEARINGS
BEARING Refer to Figure 14.
Refer to Figure 13.
Disassembly
Disassembly
1. Remove the swashplate (32).
1. Remove the block spring (29).
Inspection
2. Remove the block thrust washer (30).
1. Inspect the running surface of the bearing pocket
3. Remove the thrust bearing and race (34). for damage (32), nicks or unusual wear patterns.
The running surface may show evidence of
Inspection
minor abrasion. This is normal wear. Inspect
1. Inspect and replace the block spring (29) the cradle bearing side of the swashplate (32)
and thrust washer (30) if they are distorted or for damage. Replace if necessary.
broken.
2. Inspect the cradle bearings attached to the inside
2. Inspect the running surface of the bearing race of the housing (1) for normal wear patterns,
for damage, nicks or unusual wear patterns. The placement, and insure they are staked securely
running surface may show evidence of minor in place. If damaged, replace housing (1).
abrasion. This will be normal wear.
NOTE: The cradle bearings will have
Inspect the bearings for free movement. Inspect discoloration due to normal wear. Under
the bearing cage for distortion or damage.
normal circumstances, this will not war-
rant replacement.
Assembly
Assembly
1. Install thrust bearing and race assembly (34).
1. Install swashplate (32) by holding trunnion
NOTE: The difference in race thick- arms (37) slot guide (38) with the aide of a flat
nesses: The thin race seats into the tip screwdriver. Use the screwdriver to hold the
swashplate (32). The thicker race will be slot guide (38) in place while positioning the
installed toward the piston noses. swashplate (32) onto the cradle bearing in the
housing (1).
2. Install thrust washer (30).
2. Rotate trunnion arm (37) to assure swashplate
3. Install block spring (29).
pivoting action.
34
32
34
30 38
30 29
37
29
1
(Cradle bearings cannot be
removed from housing as depicted)
Figure 14. PG / PE Pump Swashplate and

Figure 13. PG / PE Pump Block Spring and Thrust Cradle Bearings
Bearing
48 PG / PE Series
REMOVAL, INSPECTION AND NOTE: If trunnion arm is to be removed,
ASSEMBLY OF INPUT SHAFT delay reassembly of input shaft assem-
bly.
Refer to Figure 15.
Disassembly Assembly
1. Remove the retaining ring (22). NOTE: Upon removal, it is recommended

that all seals, O-rings and gaskets be re-
2. Remove the lip seal (20). placed. During installation, lightly lubri-
3. Remove the spacer (21).
4. Remove the shaft (18) from the pump. Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
Inspection
1. Inspect the input shaft (18) for worn splines, 1. Install input shaft assembly (18, 19, 23) into the
surface damage, or keyway damage. Replace housing (1) bore. Light tapping with a rubber
shaft assembly if necessary. mallet may be necessary on the input shaft (18)
once the bearing is aligned with the housing (1)
2. Inspect the bearing (19) for evidence of scoring, bore. Rotate the input shaft (18) to insure free
corrosion, or damage. Replace shaft assembly movement.
if necessary.
2. Install spacer (21).
3. Inspect and replace the spacer (21) if it is bent
or broken. 3. Install new lip seal (20).
4. Inspect and replace the retaining ring (22) if it 4. Remove the plastic wrap.
is bent or broken.
5. Install retaining ring (22).
NOTE: Replace the input shaft seal (20)

after removal.
22
20
21
23
19
18
Figure 15. PG / PE Pump Input Shaft
PG / PE Series 49
REMOVAL AND INSPECTION OF
TRUNNION ARM
Refer to Figure 16.
1
Disassembly
1. Remove the slot guide (38).
2. Remove and discard the trunnion seal retainer

and seal (49).
38
3. Remove the trunnion arm (37).
Inspection 37
49
1. Inspect the trunnion arm (37) for wear or damage.
Replace the trunnion arm if necessary.
Figure 16. PG / PE Pump Trunnion Arm
Assembly
1. Install the trunnion arm (37) into the housing

(1) bore. Rotate the trunnion arm to verify free
movement.
NOTE: Upon removal, it is recommended

that all seals, O-rings, and gaskets be re-
placed. During installation, lightly lubri-
Also protect the inner diameter of seals
Remove the plastic wrap after the seal
is installed.
2. Install a new seal and seal retainer (49).
3. Install the slot guide (38).
4. To completely reassemble the pump, refer to

the assembly steps on pages 39-50. Begin
with the trunnion arm assembly steps listed on
page 54 and complete the assembly steps in
reverse order working towards the front of the
manual.
50 PG / PE Series
PG / PE Series 51
52
Figure 17. PG / PE Pump
Kit Number
PG / PE Series
ITEM LIST - pg and PE SERIES

1 Housing Kit 34 Ball Thrust Bearing
2 End Cap Kit (W/Poppets, Standard Charge) 35 Stud, Torque
End Cap Kit (W/ SCRS, Standard Charge) 37 Trunnion Arm
End Cap Kit (W/ Poppets, Auxiliary Charge) Trunnion, RTN
End Cap Kit (W/ SCRS, Auxiliary Charge) 38 Slot Guide
End Cap Kit (STD CHG) LH;SCR/HR: Poppet 42 Check Valve Kit (blank Orifice)
End Cap Kit (STD CHG) LH:Poppet/RH:SCR Check Valve Kit (0.024 Orifice)
End Cap Kit (STD CHG) LH:SCR/RH:SCR Check Valve Kit (0.031 Orifice)
End Cap Kit (AUX CHG) LH:SCR/RH:Poppet Check Valve Kit (0.044 Orifice)
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR System Check / Relief Kit
End Cap Kit (AUX CHG) LH:SCR/RHPoppet, System Check Relief Kit (.031 Orifice)
Thru Shock Valve Kit
End Cap Kit (AUX CHG) W/Poppets, Thru 44 Charge Relief Valve Kit (1/4 Plastic Ball
End Cap Kit (AUX CHG) W/SCR;s, Thru & 50654 Spring)
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Charge Relief Valve Kit (9/16 SAE Plug
Thru & 3101536 Spring)
3 Straight Headless Pin 45 Aux Relief Valve Kit (1/4 Steel Ball)
4 Hex Flange Bolt M8-1.25 X 60 mm LG Aux Relief Valve Kit (Aux Poppet)
5 Housing O-Ring 49 Trunnion Seal/Retainer Kit
6 Charge Pump Kit (STD) 54 Auxiliary Filter Kit
Charge Pump Kit (STD CHG), Thru 56 Straight Thread Plug
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE 59 O-Ring
Ports) 64 Connector
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE 66 5/16 SAE Plug
Ports) 67 Filter Cover
7 STD Gerotor Assy (.11 cu. In/rev D-Drive) 69 Straight Headless Pin
Auxiliary Gerotor & Housing Assembly 75 Shim - Charge Pump (.002 - Red)
8 O-Ring 85 R-Ring - 144
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD 90 Hub / 6 Fan Kit
Chg) Hub / 7 CCW Fan Kit
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg) Hub / 7 CW Fan Kit
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg) Hug / 7 Fan Kit
Supplied with item # 2 only 94 Control Arm
15 Bypass Valve Kit (Blank) 95 Screw, Soc Head
Bypass Valve Kit (0.031) 98 Return Arm
Bypass Valve Kit (0.043) 99 Inner Scissor Arm
18 Pump Shaft Kit (Blind 15mm Keyway 100 Outer Scissor Arm
W/Std Chg) 101 Spacer RTN
Pump Shaft Kit (Blind 15mm Keyway 102 Spring, Extension
W/Aux Chg) 103 Screw, 5/16 x .875 (patch)
Pump Shaft Kit (9 Tooth W/Std Chg) 104 Washer .34 x .88 x .06
Pump Shaft Kit (9 Tooth W/Aux Chg) 105 Washer, Nylon
Pump Shaft Kit (15mm Keyed, Std Chg, Thru) 106 Bolt
Pump Shaft Kit (9 Tooth Thru Chg) 107 Nut, Hex
Pump Shaft Kit (Tapered) 110 Kit, RTN, STD
19 Ball Bearing 17 X 40 X 12 Kit, RTN, CW
20 Lip Seal 17 X 40 X 7 PTC Kit, RTN, CCW
21 Spacer 111 Seal Kit
22 Retaining Ring 209 Shroud Bracket
25 Cylinder Block Kit 210 Shroud
29 Block Spring
30 Block Thrust Washer
31 Valve Plate
32 Swashplate
PG / PE Series 53
54 PG / PE Series
REPAIR - PJ SERIES PUMP
Repair - PJ Series Pump ...................................................................................................... 55-72
Fan Assembly .............................................................................................................................. 58
Input Shaft Seal ........................................................................................................................... 59
Check Valves ............................................................................................................................... 60
Shock Valves ............................................................................................................................... 60
Bypass ........................................................................................................................................ 61
Auxiliary Pump ............................................................................................................................. 63
End Cap ...................................................................................................................................... 64
Cylinder Block ............................................................................................................................. 65
Block Spring and Thrust Bearings ...............................................................................................66
Input Shaft ................................................................................................................................... 67
Trunnion Arm ............................................................................................................................... 68
Parts List ............................................................................................................................... 70-71

for part names and descriptions. A complete these seals generally requires removal of the pump
exploded view and item list of the pump is provided from the machine. Upon removal, it is recommended
at the end of this section. that all seals, O-rings and gaskets be replaced.

PJ Series 55
TOOLS AND TORQUES

Seal Hook with a Magnet 5/8-inch Socket
Flat Blade Screwdriver 11/16-inch Socket
10-mm Socket
Pliers
Internal Snap Ring Combination Wrenches
7/16 inch
5mm 9/16 inch
1/8 inch 5/8 inch
3/16 inch 11/16 inch
1/4 inch 7/8 inch
10 mm

10, Cap Screw 180-220 lb-in (20.3-24.9 Nm)
103, Screw 5/16 x .875 200-240 lb-in (22.6-27.1 Nm)
106, Bolt 180-220 lb-in (20.3-24.9 Nm)
107, Nut, Hex Lock 5/16-24UNF 180-220 lb-in (20.3-24.9 Nm)
Table 2. PJ Pump Torque Values
56 PJ Series
PJ SERIES PUMP REPAIR
NEUTRAL ASSEMBLY
bracket.
2. Inspect scissor arm (99) and all other linkage
Disassembly parts for damage, corrosion or wear.
use care and proper protection during disassembly 1. Install the inner return arm bracket(98), washer
and assembly of the return to neutral linkage. (104) and bolt (103).
1. Loosen (but do not remove) the bolt (106)/nut NOTE: Do not over tighten the bolt (103). The
(107). bracket must move freely.
2. To relieve spring tension, carefully pry up on the 2. Install the inner scissor control arm(94)
outer scissor control arm until it releases from
the tab on the outer control arm bracket. 3. Tighten washer (104), and nut (103) to the
correct torque value. See page 74.
3. Remove the spring (102), bolt (106)/nut (107)
and washer (104). 4. Install the scissor arm(99).
4. Remove the scissor arm (99). 5. Install washer(104) and bolt (106)/nut (107) to
5. Remove the outer control arm bracket(94), bolt
(103), washer (104) and the inner return arm 5. Install the spring (102).
bracket(98).
104
107
Figure 1. PJ Pump Return to Neutral
PJ Series 57
1. Remove the bolt (106)/nut (107), washer (104) 1. Remove the fan shroud (210) from the mounting
and bushing (101). bracket (209) by carefully pushing down on the
shroud tabs.
(104) and bolt (103). 56.
(101), washer (104, and bolt (106)/nut(107). 56.
56. 4. Install the fan shroud (210) onto the mounting
slots.
104 209
107
10
Figure 2. PJ Pump Standard Control Arm
106
90
210
Figure 3. PJ Pump Fan Assembly
58 PJ Series
SEAL SEAL
Inspection
Inspection
2. Wrap the input shaft with plastic wrap to prevent with petroleum jelly.
damage to the inner surface of the lip seal (20).
2. Wrap the trunnion arm with plastic wrap to
3. Slide spacer (21) and seal (20) over the input prevent damage to the inner surface of the lip
shaft so that lettering on the seal faces out. seal (49).
4. Press the lip seal (20) into the housing bore. 3. Slide the lip seal (49) over the trunnion arm so that
Insure the lip seal (20), input shaft or housing the lettering on the seal (49) faces out.
(1) bore does not become damaged.
4. Press the lip seal (49) into the housing bore.
5. Install the retaining ring (22) into the housing bore Insure the seal (49), trunnion arm, and housing
groove. bore do not become damaged. Remove the
plastic wrap.

22
20 6. Install the RTN assembly or control arm.
21
Figure 4. PJ Pump Input Shaft Seal
49
Figure 5. PJ Pump Trunnion Arm Seal

PJ Series 59
REPLACEMENT OF CHECK VALVES REPLACEMENT OF SYSTEM CHECK
Refer to Figure 6.
RELIEFS (SCRS) OR SHOCK
VALVES
check valves one side at a time. Some units vary in
A side to B side check configuration. Refer to Figure 7.
1. Remove the check valve (42) with an 1/4 allen Perform disassembly, inspection and assembly on
wrench. SCR/shock valve one side at a time. Some units
end cap. 1. Remove the SCR (42) with a 7/8 wrench or the
Inspection
1. Inspect the poppets and mating seats in the end the check relief/shock valve from the end cap.
cap for damage or foreign material.
Inspection
Assembly
1. Inspect the check relief or shock valve (42) and
1. Lay the pump on its side, so the check plug port mating seat in the end cap for damage or foreign
is horizontal. material.
2. Insert the check plug, spring and poppet (42) as Assembly
one assembly into the check plug port. Tighten,
reference Table 2, page 56 for torque values. 1. Lay the pump on its side, so the check plug port
is horizontal.
for the opposite port side. 2. Insert the system check relief spring and check

42A
42A
42B
Figure 6. PJ Pump Check Valves
42B
Figure 7. PJ Pump Shock Valves
60 PJ Series
Refer to Figure 8.
Disassembly

wrench.
Inspection
1. Inspect the bypass O-rings and mating seats in

the end cap (2) for damage or foreign materials.
Assembly

horizontal.

value. See page 56.
15
Figure 8. PJ Pump Bypass
PJ Series 61
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum jelly.
Disassembly
2. Press the shaft seal into the charge cover. Be
1. Prior to removal of the charge pump cover, place careful not to damage the seal or charge cover
a mark on the cover and end cap for alignment bore.
at assembly.
3. Position the pump with the input shaft down, and
2. Using a 1/2 inch wrench, or 5 mm allen wrench, the end cap (2) horizontal. Place the charge ball
loosen the charge pump cover bolts (10) from (44) in the end cap (2) charge passage so the
the end cap (2). While holding the charge cover ball mates to the end cap (2) charge ball seat.
in place, remove the charge cover bolts (10). Place the charge spring, on top of the charge
ball.
3. Remove the charge cover, O-ring and gerotor
items (6). Carefully check for and remove the 4. Insert the inner gerotor over input shaft (18).
charge spring and charge ball (44).
5. Align the outer gerotor to fit over the inner gerotor.
4. For the Thru Shaft charge pump, remove the
6. Insert the O-ring (8) into the groove in the charge
shaft seal.
cover.
Inspection
7. Position the charge cover and O-ring with the
1. Inspect the charge cover O-ring and running aligning mark on the end cap. Place the charge
surfaces for damage. Inspect the spring, check cover and O-ring with aligning mark on the end
ball (44), and mating seat in the end cap (2) for cap. Place the charge cover and O-ring as one
damage or foreign material. piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
NOTE: If the end cap (2) is to be re- cover spring retaining groove.
moved from the housing, do not as-
semble the charge pump (6) until the 8. Align and insert the charge pump cover bolts
end cap is installed on the housing. (10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 56. (Torque
2. Inspect the charge cover bore for damage, Values.)
corrosion or wear.
44
6
18
THRU SHAFT
8
7
2
8
10 7 STANDARD
6
10
Figure 9. PJ Pump Standard or Thru Shaft Charge Pump

62 PJ Series
REPLACEMENT OF AUXILIARY filter for wear, damage or foreign material.
56.
mark on the auxiliary pump, charge pump (7) 2. Install the poppet, spring and cap (44) as one
and end cap (2) for alignment at assembly. assembly into the charge relief port. Tighten to
pump bolts (10) from the end cap (2). While 3. Install the filter (54) and O-ring onto the filter
holding the auxiliary pump in place, remove the cover assembly (67). Install the assembly (67)
bolts (10). into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
3. Remove the auxiliary pump, gasket (75), O-ring
(8) and charge pump (7). While removing the 4. Lay the PJ Pump (input shaft down), so the end
charge pump, be sure to retain the spring and cap is horizontal. Install the O-ring (8) into the
ball (44A) housed in the end cap (2). charge pump (7).
4. Remove the plug (66) from the filter cover (67). 5. Install the gasket (75) onto the auxiliary pump.
5. Use a 7/8 inch wrench to remove the filter cover 6. Make sure that the ball and spring (44A) are
assembly (67) from the auxiliary pump. seated in the end cap (2), then position the
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44) fully engages the alignment pins (69).
auxiliary pump.
Inspection charge pump in place, tighten the bolts (10) per
table 2, page 56.
1. With the auxiliary pump removed, inspect the
44A
44
8
69
45
54
67
2
10
64
7
8
75
66
Figure 10. Auxiliary Pump
PJ Series 63
Assembly
Refer to Figure 11.
1. Install housing gasket (5) into gasket seat of
Disassembly housing (1).
1. Remove charge pump. (See page 62). 2. Lubricate the cylinder block (25) to end cap (2)
mating surface with clean oil prior to installation.
2. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly. 3. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (92)
3. Hold the end cap (2) in place and remove the verifying alignment and insuring that the
four end cap bolts (4). cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten to the correct
4. Slowly remove the end cap (2).
torque value. See Table 2, page 56 (Torque
5. Remove housing gasket (5). Values).
Inspection 4. Install the charge pump. (See page 62.)


the cylinder block) of the end cap (2). The
running surface may show evidence of minor
abrasive rings, this is normal.
Grooving in the end cap, or material transfer that

is evident when the surface is checked by
dragging a fingernail across it, would be cause
for replacement of the end cap (2).
1
4
25
4 2
5
Figure 11. PJ Pump End Cap
64 PJ Series
BLOCK
4. Install each piston, spring and seat assembly
Refer to Figure 12. into the cylinder block.
Disassembly 5. With the pump housing tilted on its side, install

the cylinder block assembly (25) with pistons
1. Remove charge pump. (See page 62). contacting the thrust bearing.
NOTE: To check if the cylinder block as-
3. Tilt the pump on its side and drain remaining oil. sembly is installed correctly, position the
Lift out the cylinder block assembly (25). pump housing vertically and support
housing at the mounting flange. Push
down on the cylinder block. The cylin-
Inspection der block must move up and down freely.
If it does not, remove the cylinder block
assembly. Place a rubber band around
the cylinder block pistons to hold them
wear patterns. The running surface may show
evidence of minor abrasion. This will be normal in position during installation. Then af-
wear. If grooved or smeared, replace with a new ter installation cut the rubber band and
cylinder block assembly. remove it. Check cylinder block assem-
bly for spring action.
2. Inspect the piston springs for distortion or breaks.
If necessary, replace with a new cylinder block
kit.
6. Install the end cap. (See page 64)
these to remain stuck to the inside of the pistons. 7. Install the charge pump. (See page 62)
Assembly

springs.
25
Figure 12. PJ Pump Cylinder Block
PJ Series 65
1. Remove the block spring (29). 1. Remove the swashplate (32).
2. Remove the block thrust washer (30) and thrust Inspection
bearing (34).
Inspection of swashplate (32) for damage, nicks or unusual
1. Inspect and replace the block spring (29) if it is
evidence of minor abrasion. This is normal wear.
distorted or broken.
of the housing (1) for normal wear patterns and
Replace if necessary. NOTE: The cradle bearings will have dis-
coloration due to normal wear. Under
Assembly
1. Install thrust bearing and race assembly (34). rant replacement.
2. Install the block thrust washer (30). Assembly

NOTE: The difference in race thick- slot guide (38) with a flat tip screwdriver. Use
nesses: The thin race seats into the the screwdriver to hold the slot guide in place
swashplate (32). The thicker race will be while positioning the swashplate (32) onto the
installed toward the piston noses.
2. Rotate trunnion arm (37) to verify that the
3. Install block spring (29). swashplate moves freely.
32
38
37
34
30
29
1
49
Figure 14. PJ Pump Swashplate and Cradle

Figure 13. Pump Block Spring and Thrust Bearing Bearings
66 PJ Series
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
Refer to Figure 15. do not assemble input shaft until the trun-
Disassembly
1. Remove the retaining ring (22). NOTE: During installation, lightly lubri-
2. Remove the lip seal (20). cate all seals, O-rings and gaskets with
3. Remove the spacer (21). Also, protect the inner diameter of seals
4. Remove the shaft (18) and bearing (19) by covering the shaft with plastic wrap.
assembly from the pump.
1. If removed, press bearing (19) onto shaft (18)
Inspection tight against the shoulder of the shaft. Install
retaining ring onto the shaft (18).
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace 2. Install input shaft assembly (18) into the housing
shaft assembly if necessary. (1) bore. Light tapping with a rubber mallet may
be necessary on the input shaft (18) once the
2. Inspect the bearing (19) for evidence of scoring, bearing is aligned with the housing (1) bore.
corrosion, or damage. If the bearing must be Verify that the shaft rotates smoothly.
replaced, remove the retaining ring and use a
press or bearing puller to remove the bearing. 3. Install spacer (21).
3. Inspect and replace the spacer (21) if it is bent 4. Install new lip seal (20) with the flat side of the
or broken. seal toward the outside of the pump.
4. Inspect and replace the retaining ring (22) if it is 5. Remove the plastic wrap.
bent or broken.
22
20
21
19
18
Figure 15. PJ Pump Input Shaft
PJ Series 67
Refer to Figure 16.
movement.
Disassembly
3. Install slot guide (38).
4. To completely assembly the pump, refer to the
and seal (49).
assembly steps on pages 57-68. Begin with the
3. Remove the trunnion arm (37). trunnion arm assembly steps listed on page 68
and complete the assembly steps in reverse
Inspection order working toward the front of the manual.
32
1. Inspect the trunnion arm (37) for wear or
damage. Replace the trunnion arm if necessary. 38
2. Check for excessive play between trunnion arm 37
(37) and housing (1). Replace housing if

necessary.
1
49
Figure 16. PJ Pump Trunnion Arm
68 PJ Series
PJ Series 69
70
Figure 17. PJ Pump
Kit Number
PJ Series
ITEM LIST - PJ SERIES

End Cap Kit (AUX CHG) LH:SCR/RHPoppet, Thru System Check Relief Kit (.031 Orifice)
End Cap Kit (AUX CHG) W/Poppets, Thru Shock Valve Kit
End Cap Kit (AUX CHG) W/SCR;s, Thru 44 Charge Relief Valve Kit (1/4 Plastic Ball
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Thru & 50654 Spring)
3 Straight Headless Pin Charge Relief Valve Kit (9/16 SAE Plug
4 Hex Flange Bolt M8-1.25 X 60 mm LG & 3101536 Spring)
5 Housing O-Ring 45 Aux Relief Valve Kit (1/4 Steel Ball)
6 Charge Pump Kit (STD) Aux Relief Valve Kit (Aux Poppet)
Charge Pump Kit (STD CHG), Thru 49 Trunnion Seal/Retainer Kit
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE 54 Auxiliary Filter Kit
Ports) 55 Plate, Adapter (Gear A)
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE 56 Straight Thread Plug
Ports) 59 O-Ring
7 STD Gerotor Assy (.11 cu. In/rev D-Drive) 64 Connector
Auxiliary Gerotor & Housing Assembly 66 5/16 SAE Plug
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD 69 Straight Headless Pin
CHg) 75 Shim - Charge Pump (.002 - Red)
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg) 80 Pin, Straight Headless
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg) 85 R-Ring - 144
Supplied with item # 2 only 90 Hub / 6 Fan Kit
15 Bypass Valve Kit (Blank) Hub / 7 CCW Fan Kit
Bypass Valve Kit (0.031) Hub / 7 CW Fan Kit
Bypass Valve Kit (0.043) Hug / 7 Fan Kit
18 Pump Shaft Kit (Blind 15mm Keyway 98 Return Arm
W/Std Chg) 99 Inner Scissor Arm
Pump Shaft Kit (Blind 15mm Keyway 100 Seal Kit
W/Aux Chg) 101 Spacer RTN
Pump Shaft Kit (9 Tooth W/Std Chg) 102 Spring, Extension
Pump Shaft Kit (9 Tooth W/Aux Chg) 103 Screw, 5/16 x .875 (patch)
Pump Shaft Kit (15mm Keyed, Std Chg, Thru) 104 Washer .34 x .88 x .06
Pump Shaft Kit (9 Tooth Thru Chg) 105 Washer, Nylon
Pump Shaft Kit (Tapered) 106 Bolt
19 Ball Bearing 17 X 40 X 12 107 Nut, Hex Lock 5/16 - 24 UNF
20 Lip Seal 17 X 40 X 7 PTC 110 Kit, RTN, STD
21 Spacer Kit, RTN, CW
22 Retaining Ring Kit, RTN, CCW
25 Cylinder Block Kit 209 Shroud Bracket
29 Block Spring 210 Shroud
32 Swashplate
PJ Series 71
72 PJ Series
REPAIR - PK SERIES PUMP
Repair - PK Series Pump ...................................................................................................... 73-90
Fan Assembly .............................................................................................................................. 76
Input Shaft Seal ........................................................................................................................... 77
Check Valves ............................................................................................................................... 78
Shock Valves ............................................................................................................................... 78
Bypass ........................................................................................................................................ 79
Auxiliary Pump ............................................................................................................................. 81
End Cap ...................................................................................................................................... 82
Cylinder Block ............................................................................................................................. 83
Block Spring and Thrust Bearings ...............................................................................................84
Input Shaft ................................................................................................................................... 85
Trunnion Arm ............................................................................................................................... 86
Parts List ............................................................................................................................... 88-89

for part names and descriptions. A complete these seals generally requires removal of the pump
exploded view and item list of the pump is provided from the machine. Upon removal, it is recommended
at the end of this section. that all seals, O-rings and gaskets be replaced.

PK Series 73
TOOLS AND TORQUES

Seal Hook with a Magnet 5/8-inch Socket
Flat Blade Screwdriver 11/16-inch Socket
10-mm Socket
Pliers
Internal Snap Ring Combination Wrenches
7/16 inch
5mm 9/16 inch
1/8 inch 5/8 inch
3/16 inch 11/16 inch
1/4 inch 7/8 inch
10 mm

10, Cap Screw 180-220 lb-in (20.3-24.9 Nm)
103, Screw 5/16 x .875 200-240 lb-in (22.6-27.1 Nm)
106, Bolt 180-220 lb-in (20.3-24.9 Nm)
Table 2. PK Pump Torque Values
74 PK Series
PK SERIES PUMP REPAIR
NEUTRAL ASSEMBLY
bracket.
2. Inspect scissor arm (99) and all other linkage
Disassembly parts for damage, corrosion or wear.
use care and proper protection during disassembly 1. Install the inner return arm bracket(98), washer
and assembly of the return to neutral linkage. (104) and bolt (103).
1. Loosen (but do not remove) the bolt (106). NOTE: Do not over tighten the bolt (103). The
outer scissor control arm until it releases from 2. Install the inner scissor control arm(94)
the tab on the outer control arm bracket.
3. Tighten washer (104), and nut (103) to the
3. Remove the spring (102), bolt(106) washer correct torque value. See page 74.
(104).
4. Install the scissor arm(99).
4. Remove the scissor arm (99).
5. Install washer(104) and bolt (106) to the correct
5. Remove the outer control arm bracket(94), bolt torque value. See page 74.
(103), washer (104) and the inner return arm
bracket(98). 5. Install the spring (102).
Figure 1. PK Pump Return to Neutral
PK Series 75
shroud tabs.

(104) and bolt (103). 74.
(101), washer (104, and bolt (106). Tighten to 74.
4. Install the fan shroud (210) onto the mounting
slots.
209
10
Figure 2. PK Pump Standard Control Arm

106
90
210
Figure 3. PK Pump Fan Assembly
76 PK Series
SEAL SEAL
Inspection
Inspection
2. Wrap the input shaft with plastic wrap to prevent with petroleum jelly.
damage to the inner surface of the lip seal (20).
2. Wrap the trunnion arm with plastic wrap to
3. Slide spacer (21) and seal (20) over the input prevent damage to the inner surface of the lip
shaft so that lettering on the seal faces out. seal (49).
4. Press the lip seal (20) into the housing bore. 3. Slide the lip seal (49) over the trunnion arm so that
Insure the lip seal (20), input shaft or housing the lettering on the seal (49) faces out.
(1) bore does not become damaged.
4. Press the lip seal (49) into the housing bore.
5. Install the retaining ring (22) into the housing bore Insure the seal (49), trunnion arm, and housing
groove. bore do not become damaged. Remove the
plastic wrap.

22
20 6. Install the RTN assembly or control arm.
21
Figure 4. PK Pump Input Shaft Seal
49
Figure 5. PK Pump Trunnion Arm Seal

PK Series 77
REPLACEMENT OF CHECK VALVES REPLACEMENT OF SYSTEM CHECK
Refer to Figure 6.
RELIEFS (SCRS) OR SHOCK
VALVES
check valves one side at a time. Some units vary in
A side to B side check configuration. Refer to Figure 7.
end cap. 1. Remove the SCR (42) with a 7/8 wrench or the
Inspection
1. Inspect the poppets and mating seats in the end the check relief/shock valve from the end cap.
cap for damage or foreign material.
Inspection
Assembly
1. Inspect the check relief or shock valve (42) and
1. Lay the pump on its side, so the check plug port mating seat in the end cap for damage or foreign
is horizontal. material.
2. Insert the check plug, spring and poppet (42) as Assembly
one assembly into the check plug port. Tighten,
reference Table 2, page 74 for torque values. 1. Lay the pump on its side, so the check plug port
is horizontal.
for the opposite port side. 2. Insert the system check relief spring and check

42A
42A
42B
Figure 6. PK Pump Check Valves
42B
Figure 7. PK Pump Shock Valves
78 PK Series
Refer to Figure 8.
Disassembly

wrench.
Inspection
1. Inspect the bypass O-rings and mating seats in

the end cap (2) for damage or foreign materials.
Assembly

horizontal.

value. See page 74.
15
Figure 8. PK Pump Bypass
PK Series 79
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum jelly.
Disassembly
2. Press the shaft seal into the charge cover. Be
1. Prior to removal of the charge pump cover, place careful not to damage the seal or charge cover
a mark on the cover and end cap for alignment bore.
at assembly.
3. Position the pump with the input shaft down, and
2. Using a 1/2 inch wrench, or 5 mm allen wrench, the end cap (2) horizontal. Place the charge ball
loosen the charge pump cover bolts (10) from (44) in the end cap (2) charge passage so the
the end cap (2). While holding the charge cover ball mates to the end cap (2) charge ball seat.
in place, remove the charge cover bolts (10). Place the charge spring, on top of the charge
ball.
3. Remove the charge cover, O-ring and gerotor
items (6). Carefully check for and remove the 4. Insert the inner gerotor over input shaft (18).
charge spring and charge ball (44).
5. Align the outer gerotor to fit over the inner gerotor.
4. For the Thru Shaft charge pump, remove the
6. Insert the O-ring (8) into the groove in the charge
shaft seal.
cover.
Inspection
7. Position the charge cover and O-ring with the
1. Inspect the charge cover O-ring and running aligning mark on the end cap. Place the charge
surfaces for damage. Inspect the spring, check cover and O-ring with aligning mark on the end
ball (44), and mating seat in the end cap (2) for cap. Place the charge cover and O-ring as one
damage or foreign material. piece over the charge spring and gerotor
assembly. Insure the spring fits into the charge
NOTE: If the end cap (2) is to be re- cover spring retaining groove.
moved from the housing, do not as-
semble the charge pump (6) until the 8. Align and insert the charge pump cover bolts
end cap is installed on the housing. (10) into the end cap (2). Tighten to the correct
torque value. See Table 2, page 74. (Torque
2. Inspect the charge cover bore for damage, Values.)
corrosion or wear.
44
6
18
THRU SHAFT
8
7
2
8
10 7 STANDARD
6
10
Figure 9. PK Pump Standard or Thru Shaft Charge Pump

80 PK Series
REPLACEMENT OF AUXILIARY filter for wear, damage or foreign material.
74.
mark on the auxiliary pump, charge pump (7) 2. Install the poppet, spring and cap (44) as one
and end cap (2) for alignment at assembly. assembly into the charge relief port. Tighten to
pump bolts (10) from the end cap (2). While 3. Install the filter (54) and O-ring onto the filter
holding the auxiliary pump in place, remove the cover assembly (67). Install the assembly (67)
bolts (10). into the auxiliary pump and tighten. Install plug
(66) into the filter cover (67).
3. Remove the auxiliary pump, gasket (75), O-ring
(8) and charge pump (7). While removing the 4. Lay the PJ Pump (input shaft down), so the end
charge pump, be sure to retain the spring and cap is horizontal. Install the O-ring (8) into the
ball (44A) housed in the end cap (2). charge pump (7).
4. Remove the plug (66) from the filter cover (67). 5. Install the gasket (75) onto the auxiliary pump.
5. Use a 7/8 inch wrench to remove the filter cover 6. Make sure that the ball and spring (44A) are
assembly (67) from the auxiliary pump. seated in the end cap (2), then position the
6. Remove the O-ring and filter (54).
7. Remove the charge relief valve assembly (44) fully engages the alignment pins (69).
auxiliary pump.
Inspection charge pump in place, tighten the bolts (10) per
table 2, page 74.
1. With the auxiliary pump removed, inspect the
44A
44
8
69
45
54
67
2
10
64
7
8
75
66
Figure 10. Auxiliary Pump
PK Series 81
Assembly
Refer to Figure 11.
1. Install housing gasket (5) into gasket seat of
Disassembly housing (1).
1. Remove charge pump. (See page 62). 2. Lubricate the cylinder block (25) to end cap (2)
mating surface with clean oil prior to installation.
2. Using a 10 mm wrench, loosen the end cap bolts
(4) evenly. 3. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (92)
3. Hold the end cap (2) in place and remove the verifying alignment and insuring that the
four end cap bolts (4). cylinder block pistons spring back and forth.
Install end cap bolts (4). Tighten to the correct
torque value. See Table 2, page 74 (Torque
5. Remove housing gasket (5). Values).
Inspection 4. Install the charge pump. (See page 80.)


the cylinder block) of the end cap (2). The
abrasive rings, this is normal.
Grooving in the end cap, or material transfer that

is evident when the surface is checked by
dragging a fingernail across it, would be cause
for replacement of the end cap (2).
1
4
25
4 2
5
Figure 11. PK Pump End Cap
82 PK Series
BLOCK
4. Install each piston, spring and seat assembly
Refer to Figure 12. into the cylinder block.
Disassembly 5. With the pump housing tilted on its side, install

the cylinder block assembly (25) with pistons
1. Remove charge pump. (See page 80. contacting the thrust bearing.
NOTE: To check if the cylinder block as-
3. Tilt the pump on its side and drain remaining oil. sembly is installed correctly, position the
Lift out the cylinder block assembly (25). pump housing vertically and support
housing at the mounting flange. Push
down on the cylinder block. The cylin-
Inspection der block must move up and down freely.
If it does not, remove the cylinder block
assembly. Place a rubber band around
the cylinder block pistons to hold them
evidence of minor abrasion. This will be normal in position during installation. Then af-
wear. If grooved or smeared, replace with a new ter installation cut the rubber band and
cylinder block assembly. remove it. Check cylinder block assem-
bly for spring action.
2. Inspect the piston springs for distortion or breaks.
If necessary, replace with a new cylinder block
kit.
6. Install the end cap. (See page 82)
these to remain stuck to the inside of the pistons. 7. Install the charge pump. (See page 80)
Assembly

springs.
25
Figure 12. PK Pump Cylinder Block
PK Series 83
1. Remove the block spring (29). 1. Remove the swashplate (32).
2. Remove the block thrust washer (30) and thrust Inspection
bearing (34).
Inspection of swashplate (32) for damage, nicks or unusual
1. Inspect and replace the block spring (29) if it is
evidence of minor abrasion. This is normal wear.
distorted or broken.
of the housing (1) for normal wear patterns and
NOTE: The cradle bearings will have dis-
Assembly coloration due to normal wear. Under
1. Install thrust bearing and race assembly (34). normal circumstances, this will not war-
rant replacement.
2. Install the block thrust washer (30).
Assembly
NOTE: The difference in race thick- 1. Install swashplate (32) by holding trunnion arms
nesses: The thin race seats into the slot guide (38) with a flat tip screwdriver. Use
swashplate (32). The thicker race will be the screwdriver to hold the slot guide in place
installed toward the piston noses. while positioning the swashplate (32) onto the
3. Install block spring (29). 2. Rotate trunnion arm (37) to verify that the
swashplate moves freely.
32
38
37
34
30
29
1
49
Figure 14. PK Pump Swashplate and Cradle

Figure 13. Pump Block Spring and Thrust Bearing
Bearings
84 PK Series
ASSEMBLY OF INPUT SHAFT
NOTE: If trunnion arm is to be removed,
Refer to Figure 15. do not assemble input shaft until the trun-
Disassembly
1. Remove the retaining ring (22). NOTE: During installation, lightly lubri-
2. Remove the lip seal (20). cate all seals, O-rings and gaskets with
3. Remove the spacer (21). Also, protect the inner diameter of seals
4. Remove the shaft (18) and bearing (19) by covering the shaft with plastic wrap.
assembly from the pump.
1. If removed, press bearing (19) onto shaft (18)
Inspection tight against the shoulder of the shaft. Install
retaining ring onto the shaft (18).
surface damage, or keyway damage. Replace 2. Install input shaft assembly (18) into the housing
shaft assembly if necessary. (1) bore. Light tapping with a rubber mallet may
be necessary on the input shaft (18) once the
2. Inspect the bearing (19) for evidence of scoring, bearing is aligned with the housing (1) bore.
corrosion, or damage. If the bearing must be Verify that the shaft rotates smoothly.
replaced, remove the retaining ring and use a
press or bearing puller to remove the bearing. 3. Install spacer (21).
3. Inspect and replace the spacer (21) if it is bent 4. Install new lip seal (20) with the flat side of the
or broken. seal toward the outside of the pump.
4. Inspect and replace the retaining ring (22) if it is 5. Remove the plastic wrap.
bent or broken.
22
20
21
19
18
Figure 15. PK Pump Input Shaft
PK Series 85
Refer to Figure 16.
movement.
Disassembly
3. Install slot guide (38).
4. To completely assembly the pump, refer to the
and seal (49).
assembly steps on pages 75-86. Begin with the
3. Remove the trunnion arm (37). trunnion arm assembly steps listed on page 86
and complete the assembly steps in reverse
Inspection order working toward the front of the manual.
32
1. Inspect the trunnion arm (37) for wear or
damage. Replace the trunnion arm if necessary. 38
2. Check for excessive play between trunnion arm 37

(37) and housing (1). Replace housing if
necessary.
1
49
Figure 16. PK Pump Trunnion Arm
86 PK Series
PK Series 87
88
Figure 17. PK Pump
Kit Number
PK Series
ITEM LIST - PK SERIES
Part numbers are not provided in this manual. See website for part numbers.

End Cap Kit (AUX CHG) LH:SCR/RHPoppet, Thru System Check Relief Kit (.031 Orifice)
End Cap Kit (AUX CHG) W/Poppets, Thru Shock Valve Kit
End Cap Kit (AUX CHG) W/SCR;s, Thru 44 Charge Relief Valve Kit (1/4 Plastic Ball
End Cap Kit (AUX CHG) LH:Poppet/RH:SCR, Thru & 50654 Spring)
3 Straight Headless Pin Charge Relief Valve Kit (9/16 SAE Plug
4 Hex Flange Bolt M8-1.25 X 60 mm LG & 3101536 Spring)
5 Housing O-Ring 45 Aux Relief Valve Kit (1/4 Steel Ball)
6 Charge Pump Kit (STD) Aux Relief Valve Kit (Aux Poppet)
Charge Pump Kit (STD CHG), Thru 49 Trunnion Seal/Retainer Kit
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE 54 Auxiliary Filter Kit
Ports) 55 Plate, Adapter (Gear A)
Aux Pump Kit (AL., 15T Splined, 3-7/16 SAE 56 Straight Thread Plug
Ports) 59 O-Ring
7 STD Gerotor Assy (.11 cu. In/rev D-Drive) 64 Connector
Auxiliary Gerotor & Housing Assembly 66 5/16 SAE Plug
10 Socket Head Screw M6 x 1.0-20 mm Lg (STD 69 Straight Headless Pin
CHg) 75 Shim - Charge Pump (.002 - Red)
Hex Flange Bolt 8M-1.25 x 60 mm (Aux Chg) 80 Pin, Straight Headless
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg) 85 R-Ring - 144
Supplied with item # 2 only 90 Hub / 6 Fan Kit
15 Bypass Valve Kit (Blank) Hub / 7 CCW Fan Kit
Bypass Valve Kit (0.031) Hub / 7 CW Fan Kit
Bypass Valve Kit (0.043) Hug / 7 Fan Kit
18 Pump Shaft Kit (Blind 15mm Keyway 98 Return Arm
W/Std Chg) 99 Scissor Arm
Pump Shaft Kit (Blind 15mm Keyway 100 Seal Kit
W/Aux Chg) 101 Spacer RTN
Pump Shaft Kit (9 Tooth W/Std Chg) 102 Spring, Extension
Pump Shaft Kit (9 Tooth W/Aux Chg) 103 Screw, 5/16 x .875 (patch)
Pump Shaft Kit (15mm Keyed, Std Chg, Thru) 104 Washer .34 x .88 x .06
Pump Shaft Kit (9 Tooth Thru Chg) 105 Washer, Nylon
Pump Shaft Kit (Tapered) 106 Bolt
19 Ball Bearing 17 X 40 X 12 110 Kit, RTN, STD
20 Lip Seal 17 X 40 X 7 PTC Kit, RTN, CW
21 Spacer Kit, RTN, CCW
22 Retaining Ring 209 Shroud Bracket
25 Cylinder Block Kit 210 Shroud
29 Block Spring
32 Swashplate
PK Series 89
90 PK Series
REPAIR - PR SERIES PUMP
Repair - PR Series Pump..................................................................................................... 91-108
How to Use This Manual..............................................................................................................91
General Instructions.....................................................................................................................91
Tools and Torques........................................................................................................................92
Return to Neutral Linkage.............................................................................................................93
Standard Control Arm Linkage.....................................................................................................94
Fan Assembly...............................................................................................................................94
Input Shaft Seal............................................................................................................................95
Trunnion Arm Seal........................................................................................................................95
Check Valves................................................................................................................................96
Shock Valves................................................................................................................................96
Bypass..........................................................................................................................................97
Charge Pump-Standard or Thru Shaft..........................................................................................98
Auxiliary Pump..............................................................................................................................99
End Cap......................................................................................................................................100
Cylinder Block.............................................................................................................................101
Block Spring and Thrust Bearings..............................................................................................102
Swashplate and Cradle Bearings...............................................................................................102
Input Shaft..................................................................................................................................103
Trunnion Arm..............................................................................................................................104
Parts List............................................................................................................................. 106-107

view showing the parts involved. The item shaft and directional control shaft of each pump.

PR Series 91
TOOLS AND TORQUES

Pliers 1/2 inch
5/8 inch
5mm 10 mm
3/16 inch
1/4 inch

49, Aux Bypass/Check Kit 180-240 lb-in (20.3-27.1 Nm)
56, Screw 180-220 lb-in (20.3-24.9 Nm)
58, Hex Screw 255-300 lb-in (28.8-33.9 Nm)
102, Cap Screw, Socket Head M8 x 1.25 x 25 180-220 lb-in (20.3-24.9 Nm)
107, Screw, 5/16-24 x .75 200-240 lb-in (22.6-27.1 Nm)
Table 2. PR Pump Torque Values
92 PR Series
PR SERIES PUMP REPAIR
NEUTRAL ASSEMBLY
Prior to disassembly, note the position of the scis- Inspection
sor arm brackets and the tab on the outer control
arm bracket. 1. With the arm control linkage removed, inspect
the trunnion arm (13) and trunnion arm seal
See Figure 1. (12).
Disassembly 2. Inspect bushing (106) and all other linkage parts
CAUTION: The spring used on the return to neutral for damage, corrosion or wear.
linkage is under tension. To avoid possible injury, Assembly
use care and proper protection during disassembly
and assembly of the return to neutral linkage. 1. Install the inner return arm bracket (105), washer
(99) and bolt (107).
1. Loosen (but do not remove) the bolt (102).
NOTE: Do not over tighten the bolt (107). The
2. To relieve spring tension, carefully pry up on the bracket must move freely.
outer scissor control arm until it releases from
the tab on the outer control arm bracket. 2. Install the outer control arm bracket (101),
washer (109) and bushing (106).
3. Remove the spring (108), bolt (102), washer
(99) and outer scissor arm bracket (103). 3. Install the inner scissor control arm bracket
(104), washer (109), and outer scissor control
4. Remove bushing (106), washers (109), and the arm bracket (103).
inner scissor arm bracket (104).
4. Install washer (99), and bolt (102). Tighten to
5. Remove the outer control arm bracket (101), the correct torque value. See page 92
bolt (107), washer (99), and inner control arm
bracket (105). 5. Install the spring (108).
105
12
101
109
13 109
106
99 99
107 104 102
103
110
108
Figure 1. PR Pump Return to Neutral
PR Series 93
1. Remove the bolt (102), washer (99) and bushing 1. Remove the fan shroud (210) from the mounting
(106). bracket (209) by carefully pushing down on the
shroud tabs.
2. Remove the outer control arm bracket (101).
2. Remove the fan nut and fan assembly (90).
control arm bracket (105). 3. Remove the bolts (56) and bracket (209).
the trunnion arm (13) and trunnion arm seal mounting bracket (209) for damage.
(12).
Assembly
for damage, corrosion or wear. 1. To install the mounting bracket (209), align and
insert the bolts (56) into the bracket and charge
Assembly pump cover. While holding the charge cover in
place, tighten the bolts (56) per table 2, page
1. Install the inner return arm bracket (105), 92.
washer (99) and bolt (107).
2. Install the fan and washer assembly onto the
NOTE: Do not over tighten the bolt (107). The shaft.
3. Install the fan nut and tighten per table 2, page
2. Install the outer control arm bracket (101), 92.
bushing (106), washer (99), and bolt (102).
Tighten to the correct torque value. See page 4. Install the fan shroud (210) onto the mounting
92. bracket (209). Make sure that all shroud lock
slots.
105
110 209
12
101
106
99
13
102
1
99
56
107
Figure 2. PR Pump Standard Control Arm
90
210
Figure 3. PR Pump Fan Assembly

94 PR Series
Refer to Figure 5.
Refer to Figure 4.
Disassembly
Disassembly
1. Remove the retainer and lip seal (12) from the
1. Remove retaining ring (3) from housing (15).
housing (15). Care must be taken to prevent
2. Remove lip seal (6). Care must be taken to damage to the housing trunnion bore, trunnion
prevent damage to the housing bore, shaft arm (13) and sealing surface. Once removed
sealing surface, or bearing. Once removed, the the retainer and lip seal is not reusable.
Inspection
Inspection
1. With the lip seal (6) removed, inspect the spacer for corrosion and wear. Inspect the trunnion bore
(4), shaft bearing (5) and housing (15) bore. area sealing surface for damage or wear.
Assembly Assembly
1. Lubricate the new lip seal (6) with petroleum 1. Lubricate the new lip seal (12) with petroleum
jelly. jelly.
2. Wrap the input shaft (1) with plastic wrap to 2. Wrap the trunnion arm (13) with plastic wrap to
prevent damage to the inner surface of the lip prevent damage to the inner surface of the lip
seal (6). seal (12).
3. Slide the seal (6) over shaft (1) so that lettering 3. Slide the lip seal (12) over the trunnion arm (13)
on the seal (6) faces out. so that the lettering on the seal (12) faces out.
4. Press the lip seal (6) into the housing (15) bore. 4. Press the lip seal (12) into the housing bore
Insure seal (6), shaft (1) or housing (15) bore (15). Insure the seal (12), trunnion arm (13),
do not become damaged. and housing bore do not become damaged.
Remove the plastic wrap.
5. Remove the plastic wrap.
6. Install the retaining ring (3) into the housing (15) arm (13) on top of the lip seal (12). Press into
bore groove. the trunnion seal bore in the housing until the
retainer mates against the trunnion seal.
3
6
4
19
20
5 15
13
1
15
Figure 4. PR Pump Input Shaft Seal

12
Figure 5. PR Pump Trunnion Arm Seal

PR Series 95
Refer to Figure 6.
SHOCK VALVES
Disassembly
Perform disassembly, inspection and assembly on Refer to Figure 7.

in A side to B side check configuration. Disassembly
end cap (25). 1. Remove the SCR (42) with a 7/8 wrench or the
Inspection
Assembly Inspection
2. Insert the check plug, spring and poppet (42) as foreign material.
42A
(PORT A
SIDE) 3. Repeat disassembly, inspection and assembly
25
42B
OR
(PORT B
SIDE)
42A
Figure 6. PR Pump Check Valves
OR
42B
25
Figure 7. PR Pump Shock Valves
96 PR Series
Refer to Figure 8.
Disassembly

wrench.
2. Remove the bypass (50) from the end cap

(25).
Inspection

materials.
2. If damaged or worn replace bypass (50).
Assembly

horizontal.

value. See page 92.
25
50
Figure 8. PR Pump Bypass
PR Series 97
Refer to Figure 9. pump follow steps 3-8.
Disassembly 1. Lubricate the new shaft seal with petroleum

jelly.
1. Prior to removal of the charge pump cover, place
a mark on the cover and end cap for alignment 2. Press the shaft seal into the charge cover. Be
at assembly. careful not to damage the seal or charge cover
bore.
2. Using a 1/2 inch wrench loosen the charge
pump cover bolts (56) from the end cap (2). 3. Position the pump with the input shaft down, and
While holding the charge cover in place, remove the end cap (25) horizontal. Place the charge
the charge cover bolts (56). ball (44) in the end cap (25) charge passage
so the ball mates to the end cap (25) charge
3. Remove the charge cover, O-ring (39) and ball seat. Place the charge spring, on top of the
gerotor items (41). Carefully check for and charge ball.
remove the charge spring and charge ball
(44). 4. Insert the outer gerotor over input shaft.
4. For the Thru Shaft charge pump, remove the 5. Align the outer gerotor to fit over the inner
shaft seal. gerotor.
Inspection 6. Insert the O-ring (39) into the groove in the

charge cover.
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring, check 7. Position the charge cover and O-ring (39) with
ball (44), and mating seat in the end cap for the aligning mark on the end cap (25). Place the
damage or foreign material. charge cover and O-ring with aligning mark on
the end cap. Place the charge cover and O-ring
NOTE: If the end cap (2) is to be re- as one piece over the charge spring and gerotor
moved from the housing, do not as- assembly. Insure the spring fits into the charge
semble the charge pump (40) until the cover spring retaining groove.
end cap is installed on the housing.
8. Align and insert the charge pump cover bolts
Values.)
44
THRU SHAFT
40
39
41
41
37
39
56 25
STANDARD
56 40
Figure 9. PR Pump Standard or Thru Shaft Charge Pump
98 PR Series
REMOVAL, INSPECTION AND/OR 2. Inspect all O-rings, gasket and mounting
seats.
PUMP (IF EQUIPPED) 3. Inspect the filter cover assembly threads and
Refer to Figure 10.
Assembly
Disassembly
1. Install the check ball, spring, and cap as one
1. Prior to removal of the auxiliary pump, place a assembly (45) into the auxiliary relief valve port.
mark on the auxiliary pump, charge pump (41) Tighten to the correct torque value. See page
and end cap (25) for alignment at assembly. 92.
2. Use a 10mm wrench to loosen the auxiliary 2. Install the poppet, spring and cap as one
pump bolts (56) from the end cap (25). While assembly (49) into the charge relief port. Tighten
holding the auxiliary pump in place, remove the to the correct torque value. See page 92.
bolts (56).
3. Install the filter (54) and O-ring onto the filter
3. Remove the auxiliary pump, gasket, O-ring (39) cover assembly (67). Install the assembly (67)
and charge pump (41). While removing the into the auxiliary pump and tighten. Install plug
charge pump, be sure to retain the spring and (156) into the filter cover (67). See page 92 for
ball (44) housed in the end cap (25). the correct torque value.
4. Remove the plug (156) from the filter cover 4. Lay the PR pump (input shaft down), so the end
(67). cap is horizontal. Install the O-ring (39) into the
charge pump (41).
assembly (67) from the auxiliary pump. 5. Install the gasket onto the auxiliary pump.
6. Remove the O-ring and filter (54). 6. Make sure that the ball and spring (44) are
7. Remove the charge relief valve assembly (49) auxiliary pump and gasket with the aligning mark
and auxiliary relief valve assembly (45) from the on the charge pump (41). Insure that the pump
auxiliary pump. fully engages the alignment pins (69).
Inspection 7. Align and insert the bolts (56) into the auxiliary
1. With the auxiliary pump removed, inspect the pump. While holding the auxiliary pump and
pump running surfaces for wear or damage. charge pump in place, tighten the bolts (56) per
table 2, page 92.
44
69
40 41
39
39 1
49
45 25
54
168
67 158
168
56 156
Figure 10. PR Series Auxiliary Pump
PR Series 99
REMOVAL, INSPECTION AND NOTE: Grooving in the valve plate and/or end
cap, made evident when the surface is checked
ASSEMBLY OF THE END CAP AND by dragging a fingernail across it, would be
VALVE PLATE cause for replacement of the valve plate.
Refer to Figure 11. 3. Inspect and replace alignment pins (26) if bent
or distorted.
Disassembly
4. Replace the housing O-ring (28) with a new
1. Using any combination of two, 9/16 wrenches O-ring before reassembly.
or 9/16 socket and ratchet drive, loosen the
end cap bolts (58) evenly. Assembly
2. Keeping the end cap (25) held in place, remove 1. Install O-ring (28) into the O-ring seat of housing
the four end cap bolts (58). (15).
3. Slowly remove the end cap (25). 2. Install alignment pins (26) into housing (15).
4. Remove the valve plate (29). 3. Lubricate the valve plate prior to installation.
Install valve plate (29) so the bronze side of the
NOTE: This step is only applicable on PR series valve plate is facing down toward the cylinder
pumps built prior to 0216Pxxxxx. block.
5. Remove housing alignment pins (26). NOTE: This step is only applicable on PR
series pumps built prior to 0216Pxxxxx.
6. Remove housing gasket (28).
4. On pumps built without a valve plate, lubricate
Inspection the end cap (25) prior to installation.
1. Inspect the end cap (25) body for damage, 5. Install end cap (25). Before installing the four
nicks or unusual wear patterns. Replace if end cap bolts (58), push down on the end cap
necessary. (25) verifying alignment and insuring that the
Install and torque end cap bolts (58). Reference
the cylinder block) of the valve plate (29) and/
Table 2, page 92 (torque values).
or end cap (25). The running surface may
show evidence of minor abrasive rings, this is
normal.
Prior to Serial # 0216Pxxxxx On or After Serial # 0216Pxxxxx
26
26
44
44
26 15
26 15
28 4X 58
4X 58 29 28
40
40
25
25
56 56
Figure 11. PR Pump End Cap
100 PR Series
Assembly
Refer to Figure 12. 3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
Disassembly
1. Tilt the pump on its side, drain remaining oil. Lift the cylinder block assembly (38) with pistons
out the cylinder block assembly (38). contacting the thrust bearing.
Inspection
1. Inspect the running surface of the cylinder block NOTE: To check that piston placement is
and piston ends for damage, nicks or unusual correct, push downward on the cylinder
wear patterns. block assembly (38). If this results in a
The running surface may show evidence of spring action the block assembly has
minor abrasion. This will be normal wear. If been installed correctly. If this cannot be
grooved or smeared, replace with a new cylinder accomplished, remove and reassemble
block assembly. the block assembly. Place a rubber band
around the cylinder block pistons to hold
2. Inspect the piston springs for distortion or them in position during installation. Then
breaks. If necessary, replace with a new cylinder
after installation cut the rubber band and
block kit.
remove it. Check cylinder block assem-
3. Inspect the piston seats. Residual oil may bly for spring action.
pistons.
Piston (x7)
Piston
Seat (x7)
Spring (x7)
Cylinder
Block
38
Figure 12. PR Pump Cylinder Block
PR Series 101
REMOVAL, INSPECTION AND REMOVAL, INSPECTION OF
ASSEMBLY OF BLOCK SPRING, SWASHPLATE, INSPECTION OF
THRUST WASHER, AND THRUST CRADLE BEARINGS
BEARING Refer to Figure 14.
Refer to Figure 13. Disassembly
Disassembly 1. Remove the swashplate (31).
1. Remove the block spring (20). Inspection
2. Remove the thrust washer (19). 1. Inspect the running surface of the bearing pocket
3. Remove the thrust bearing and race (17). for damage (31), nicks or unusual wear patterns.
Inspection minor abrasion. This is normal wear. Inspect
the cradle bearing side of the swashplate (31)
1. Inspect and replace the block spring (20) for damage. Replace if necessary.
and thrust washer (19) if they are distorted or
broken. 2. Inspect the cradle bearings attached to the inside
of the housing (15) for normal wear patterns,
2. Inspect the running surface of the bearing race placement, and insure they are staked securely
for damage, nicks or unusual wear patterns. The in place. If damaged, replace housing (15).
NOTE: The cradle bearings will have
Inspect the bearings for free movement. Inspect discoloration due to normal wear. Under
rant replacement.
Assembly
Assembly
1. Install thrust bearing and race assembly (17).
(13) slot guide (14) with a flat tip screwdriver.
NOTE: The difference in race thickness- Use the screwdriver to hold the slot guide (14)
es: The thin race seats into the swash- in place while positioning the swashplate (31)
plate. The thicker race will be installed onto the cradle bearing in the housing (15).
toward the piston noses.
2. Rotate trunnion arm (13) to assure swashplate
2. Install thrust washer (19). pivoting action.
3. Install block spring (20).

31
17 17
19 14
20 13
19
20
15
(Cradle Bearings cannot be
Figure 13. PR Pump Block Spring and Figure 14. PR Pump Swashplate and
Thrust Bearing Cradle Bearings
102 PR Series
bly.
Refer to Figure 15.
Disassembly 5. Inspect and replace the thrust spring (20)

1. Remove the retaining ring (3). broken.
Assembly
2. Remove the lip seal (6).
3. Remove the spacer (4).
that all seals, O-rings and gaskets be re-
4. Remove the shaft assembly (1). placed. During installation, lightly lubri-
Inspection clean petroleum jelly prior to assembly.
1. Inspect the input shaft (1) for worn splines, Also, protect the inner diameter of seals
damage, or keyway damage. Replace shaft by covering the shaft with plastic wrap.
assembly if necessary.
1. Install input shaft assembly (1) into the housing
2. Inspect the bearing (5) for evidence of scoring, (15) bore. Light tapping with a rubber mallet
corrosion, or damage. Replace shaft assembly may be necessary on the input shaft (1) once
if necessary. the bearing is aligned with the housing bore
(15). Rotate the input shaft (1) to insure free
3. Inspect and replace the spacer (4) if it is bent or movement.
broken.
after removal. 3. Install new lip seal (6).

4. Inspect and replace the retaining ring (3) if it is
bent or broken.
3
6
4
2
19
20 2
5
2
15
Figure 15. PR Pump Input Shaft
PR Series 103
REMOVAL AND INSPECTION OF NOTE: Upon removal, it is recommended
TRUNNION ARM that all seals, O-rings, and gaskets be re-
Refer to Figure 16. cate all seals, O-rings and gaskets with
Disassembly clean petroleum jelly prior to assembly.
1. Remove and discard the trunnion seal retainer by covering the shaft with plastic wrap.
and seal (12). Remove the plastic wrap after the seal
2. Remove the slot guide (14). is installed.
Inspection 15

Assembly
1. Install the trunnion arm (13) into the housing 14

movement. 13
2. Install a new seal and seal retainer (12). 12
3. Install the slot guide (14). Figure 16. PR Pump Trunnion Arm

manual.
104 PR Series
PR Series 105
106
Figure 17. PR Pump
Kit Number
PR Series
ITEM LIST - PR SERIES

1 Pump Shaft Kit (19T spline) Shock Valve Kit (.031 orifice)
Pump Shaft Kit (17 mm keyed) Shock Valve Kit (.044 orifice)
Pump Shaft Kit (17 mm keyed thru taper)
Pump Shaft Kit (double tapered thru shaft) 44 Charge Relief Kit (1/4 plastic ball & spring)
3 Retaining Ring Charge Relief Kit (1/4 plastic ball & spring)
4 Spacer Charge Relief Kit (w/ 9/16 SAE valve plug
5 Shaft Ball Bearing 40-70 psi)
6 Lip Seal 17 X 47 X 8 PTCN1 Charge Relief Kit (w/ 9/16 SAE valve plug
12 Trunnion Seal Kit 75-105 psi)
13 Trunnion Arm Charge Relief Kit (w/ 1/2 SAE valve plug
14 Slot Guide 40-70 psi)
15 Housing Kit Charge Relief Kit (w/ 1/2 SAE valve plug
17 Thrust Ball Bearing Assembly 135-1650 psi)
19 Block Thrust Washer 45 Aux Relief Valve Kit
20 Block Spring 49 Aux Bypass/Check Kit
25 End Cap Kit (w/poppets & std chg) 50 Bypass Valve Kit (blank orifice)
End Cap Kit (w/poppets & aux chg) Bypass Valve Kit (.031 orifice)
26 Pin Bypass Valve Kit (.043 orifice)
28 O-Ring 54 Auxiliary Filter Kit
29 Valve Plate 56 Socket Hd Cap Screw (M8 x 1.25-25mm
31 Variable Swashplate Flange Hd Screw (5/16-18 x 2.5)
38 Cylinder Block Kit (16cc) 58 Hex Screw, Flanged Hd (M10 x 1.50-65 mm)
39 O-Ring 60 Mounting Bracket
R-Ring (-144) 67 Filter Cover
40 Charge Pump Kit (.19 std splined) 69 Dowel Pin
Charge Pump Kit (.13 std thru shaft) 90 Fan Kit
Charge Pump Kit (CW-Iron Aux, 40-70 psi, 99 Washer
.001 shim) 100 Seal Kit
Charge Pump Kit (CW-Iron Aux, 135-165 101 Control Arm
psi, 102 Screw
.001 shim) 103 Outer Scissor Arm
Charge Pump Kit (CCW-Iron Aux, 70-70 104 Inner Scissor Arm
psi, 105 Return Arm
.001 shim) 106 Spacer
Charge Pump Kit (Al Aux, 7/16 SAE port, 197 Screw
40-70 psi, .001 shim) 108 Spring
Charge Pump Kit (Al Aux 7/16 SAE port, 109 Washer
75-105 psi, .001 shim) 110 Return Kit
41 Gerotor Assembly (.13 cu.in./rev) 149 Plug
Gerotor Assembly (.19 cu.in./rev) 150 Plug
Aux Gerotor & Hsg Assembly (0.19 cu.in./ 151 Plug
rev) 152 Plug
42 Check Valve Kit (blank orifice) 153 Plug
Check Valve Kit (0.24 orifice) 156 Plug
Check Valve Kit (.031 orifice) 158 Plug
Check Valve Kit (.044 orifice) 168 Connector
Shock Valve Kit (blank orifice) 209 Shroud Bracket
Shock Valve Kit (.024 orifice) 210 Shroud
PR Series 107
108 PR Series
REPAIR - PW SERIES PUMP
Repair - PW Series Pump.................................................................................................. 109-126
How to Use This Manual............................................................................................................109
General Instructions...................................................................................................................109
Tools and Torques......................................................................................................................110
Return to Neutral Linkage........................................................................................................... 111
Standard Control Arm Linkage...................................................................................................112
Fan Assembly.............................................................................................................................112
Input Shaft Seal..........................................................................................................................113
Trunnion Arm Seal......................................................................................................................113
Check Valves..............................................................................................................................114
Shock Valves..............................................................................................................................114
Bypass........................................................................................................................................115
Charge Pump-Standard or Thru Shaft........................................................................................116
Auxiliary Pump............................................................................................................................117
End Cap......................................................................................................................................118
Cylinder Block.............................................................................................................................119
Block Spring and Thrust Bearings..............................................................................................120
Swashplate and Cradle Bearings...............................................................................................120
Input Shaft..................................................................................................................................121
Trunnion Arm..............................................................................................................................122
Parts List............................................................................................................................. 124-125

view showing the parts involved. The item shaft and directional control shaft of each Pump.

PW Series 109
TOOLS AND TORQUES

Pliers 1/2 inch
5/8 inch
5mm 10 mm
3/16 inch
1/4 inch

44, Charge Relief Kit 180-240 lb-in (20.3-27.1 Nm)
49, Aux Bypass/Check Kit 180-240 lb-in (20.3-27.1 Nm)
56, Screw 180-220 lb-in (20.3-24.9 Nm)
58, Housing Bolt 255-345 lb-in (28.8-38.9 Nm)
66, Steel Plug 55-85 lb-in (6.2-9.6 Nm)
Screw, Socket Hd.Control Arm 5/16-24 x .75 200-240 lb-in (22.6-27.1 Nm)
Screw, Socket Hd. RTN M8 x 1.25 x 25 180-220 lb-in (20.3-24.9 Nm)
Table 2. PW Pump Torque Values
110 PW Series
PW SERIES PUMP REPAIR
NEUTRAL ASSEMBLY
Prior to disassembly, note the position of the scis- Inspection
sor arm brackets and the tab on the outer control
arm bracket. 1. With the arm control linkage removed, inspect
the trunnion arm and trunnion arm seal.
See Figure 1.
Disassembly for damage, corrosion or wear.
use care and proper protection during disassembly 1. Install the inner control arm bracket (115),
and assembly of the return to neutral linkage. washer (109) and bolt (117).
1. Loosen (but do not remove) the bolt (112). NOTE: Do not over tighten the bolt (117). The
outer scissor control arm until it releases from 2. Install the outer control arm bracket (111),
the tab on the outer control arm bracket. washer (119) and bushing (116).
3. Remove the spring (18), bolt (112) washer (109) 3. Install the inner scissor arm bracket (114),
and outer scissor arm bracket (113). washer (119), and outer scissor arm bracket
(113).
4. Remove bushing (116), washer (119), and the
inner scissor control arm bracket (114). 4. Install washer (109), and bolt (112). Tighten to
5. Remove the outer control arm bracket (111),
bolt (117), washer (109), and inner control arm 5. Install the spring (18).
bracket (115).
110
109
116
112
119
113
117
119 109
18
114
111
115
Figure 1. PW Pump Return to Neutral
PW Series 111
shroud tabs.
2. Remove the outer control arm bracket (111).
2. Remove the fan nut and fan assembly (90).
control arm bracket (115). 3. Remove the bolts (56) and bracket (209).
the trunnion arm and trunnion arm seal. mounting bracket (209) for damage.

1. Install the inner return arm bracket (115), place, tighten the bolts (56) per table 2, page
washer (109) and bolt (117). 110.
2. Install the outer control arm bracket (111), 3. Install the fan nut and tighten per table 2, page
bushing (116), washer (109) and bolt (112). 110.
110. 4. Install the fan shroud (210) onto the mounting
110 slots.
112
116
117
209
109
109
111
115
56
Figure 2. PW Pump Standard Control Arm
90
210
Figure 3. PW Pump Fan Assembly

112 PW Series
1. Remove retaining ring (3) from housing (15). 1. Remove the retainer and lip seal (12). Care
must be taken to prevent damage to the housing
2. Remove lip seal (6). Care must be taken to trunnion bore, trunnion arm (13) and sealing
prevent damage to the housing bore, shaft, surface. Once removed the retainer and lip seal
sealing surface, or bearing. Once removed, the (12) is not reusable.
Inspection
Inspection
1. With the lip seal (6) removed, inspect the spacer for corrosion and wear. Inspect the trunnion bore
(4), shaft bearing (5) and housing (15) bore. area sealing surface for damage or wear.
Assembly Assembly
1. Lubricate the new lip seal (6) with petroleum 1. Lubricate the new lip seal (12) with petroleum
jelly. jelly.
2. Wrap the input shaft (1) with plastic wrap to 2. Wrap the trunnion arm (13) with plastic wrap to
prevent damage to the inner surface of the lip prevent damage to the inner surface of the lip
seal (6). seal (12).
3. Slide the seal (6) over shaft (1) so that lettering 3. Slide the lip seal (12) over the trunnion arm (13)
on the seal (6) faces out. so that the lettering on the seal (12) faces out.
4. Press the lip seal (6) into the housing (15) bore. 4. Press the lip seal (12) into the housing bore
Insure seal (6), shaft (1) or housing (15) bore (15). Insure the seal (12), trunnion arm (13),
do not become damaged. Remove the plastic and housing bore do not become damaged.
wrap. Remove the plastic wrap.
5. Install the retaining ring (3) into the housing (15) 5. Install the retainer over the trunnion arm (13) on
bore groove. top of the lip seal (12). Press into the trunnion
seal bore in the housing (15).
3
6 15
5
12
4
15
Figure 4. PW Pump Input Shaft Seal
13
Figure 5. PW Pump Trunnion Arm Seal
PW Series 113
Refer to Figure 6.
SHOCK VALVES
Disassembly
Perform disassembly, inspection and assembly on Refer to Figure 7.

in A side to B side check configuration. Disassembly
end cap (25). 1. Remove the SCR (42) with a 7/8 wrench or the
Inspection
Assembly Inspection
2. Insert the check plug, spring and poppet (42) as foreign material.
42B relief or shock valve spring and shock valve
as one assembly into the check plug port.
Tighten, reference Table 2, page 110, for torque
values.

42A
42B
OR
25 42B
Figure 6. PW Pump Check Valves

42A
OR
42A
Figure 7. PW Pump Shock Valves
114 PW Series
Refer to Figure 8.
Disassembly

wrench.
2. Remove the bypass (50) from the end cap

(25).
Inspection

materials.
Assembly

horizontal.

the end cap (25). Tighten, reference Table 2,
page 110, torque values.
50
25
Figure 8. PW Pump Bypass
PW Series 115
Refer to Figure 9.
1. Lubricate the new shaft seal with petroleum
Disassembly jelly.
a mark on the cover and end cap for alignment careful not to damage the seal or charge cover
at assembly. bore.
2. Using a 1/2 inch wrench loosen the charge 3. Position the pump with the input shaft down, and
pump cover bolts (56) from the end cap (25). the end cap (25) horizontal. Place the charge
While holding the charge cover in place, remove ball (44) in the end cap (25) charge passage
the charge cover bolts (56). so the ball mates to the end cap (25) charge
ball seat. Place the charge spring, on top of the
3. Remove the charge cover, O-ring (39) and charge ball.
gerotor items (41). Carefully check for and
remove the charge spring and charge ball 4. Insert the inner gerotor over input shaft.
(44).
5. Align the outer gerotor to fit over the inner
4. For the Thru Shaft charge pump, remove the gerotor.
shaft seal.
6. Insert the O-ring (39) into the groove in the
Inspection charge cover.
1. Inspect the charge cover O-ring and running 7. Position the charge cover and O-ring (39) with
surfaces for damage. Inspect the spring, check the aligning mark on the end cap (25). Place the
ball (44), and mating seat in the end cap (25) charge cover and O-ring with aligning mark on
for damage or foreign material. the end cap. Place the charge cover and O-ring
NOTE: If the end cap (25) is to be re- as one piece over the charge spring (44) and
moved from the housing, do not as- gerotor assembly. Insure the spring fits into the
semble the charge pump (40) until the charge cover spring retaining groove.
end cap is installed on the housing. 8. Align and insert the charge pump cover bolts
Values.)
44
THRU SHAFT 41
40
39
37
39
25
41
56
STANDARD
56 40
Figure 9. PW Pump Standard or Thru Shaft Charge Pump
116 PW Series
REMOVAL, INSPECTION AND/OR 2. Inspect all O-rings, gasket and mounting
seats.
PUMP (IF EQUIPPED) 3. Inspect the filter cover assembly threads and
Refer to Figure 10.
Assembly
Disassembly
1. Install the check ball, spring, and cap as one
1. Prior to removal of the auxiliary pump, place a assembly (45) into the auxiliary relief valve port.
mark on the auxiliary pump, charge pump (41) Tighten to the correct torque value. See page
and end cap (25) for alignment at assembly. 110.
2. Use a 10mm wrench to loosen the auxiliary 2. Install the poppet, spring and cap as one
pump bolts (56) from the end cap (25). While assembly (44) into the charge relief port. Tighten
holding the auxiliary pump in place, remove the to the correct torque value. See page 110.
bolts (56).
3. Install the filter (54) and O-ring into the filter
3. Remove the auxiliary pump, gasket, O-ring (39) cover assembly (67). Install the assembly (67)
and charge pump (41). While removing the into the auxiliary pump and tighten. Install the
charge pump, be sure to retain the spring and plug (66) into the filter cover (67).
ball (44A) housed in the end cap (25).
4. Lay the PW pump (input shaft down), so the end
4. Remove the plug (66) from the filter cover cap is horizontal. Install the O-ring (39) into the
(67). charge pump (41).
5. Use a 7/8 inch wrench to remove the filter cover 5. Install the gasket onto the auxiliary pump.
assembly (67) from the pump.
6. Make sure that the ball and spring (44A) are
6. Remove the O-ring and filter (54). seated in the end cap (25), then position the
7. Remove the charge relief valve assembly (44) on the charge pump (7). Insure that the pump
and auxiliary relief valve assembly (45) from the fully engages the alignment pins (69).
auxiliary pump.
Inspection pump. While holding the auxiliary pump and
1. With the auxiliary pump removed, inspect the charge pump in place, tighten the bolts (56) per
pump running surfaces for wear or damage. table 2, page 110.
44A
168
40
45 44
39
41
66
39
1
69 25
54 (2X) 56
67
Figure 10. PW Series Auxiliary Pump
PW Series 117
REMOVAL, INSPECTION AND NOTE: Grooving in the valve plate and/or
end cap, made evident when the surface is
ASSEMBLY OF THE END CAP AND checked by dragging a fingernail across the
VALVE PLATE surface, would be cause for replacement of
the valve plate and/or end cap.
Refer to Figure 11.
2. Inspect and replace alignment pins (26) if bent
Disassembly or distorted.
1. Using any combination of two, 9/16 wrenches 3. Replace the housing O-ring (28) with a new
or 9/16 socket and rachet drive, loosen the end O-ring before reassembly.
cap bolts (58) evenly.
Assembly
2. Keeping the end cap (25) held in place, remove
the four end cap bolts (58). 1. Install housing O-ring (28) into O-ring seat of
housing (15).
2. Install alignment pins (26) into housing (15).
4. Remove the valve plate (29).
3. Lubricate the valve plate prior to installation.
NOTE: This step is only applicable on PW series Install valve plate (29) with the bronze side
pumps built prior to 0216Pxxxxx. down, contacting the cylinder block.
5. Remove housing alignment pins (26). NOTE: This step is only applicable on PW
series pumps built prior to 0216Pxxxxx.
6. Remove housing gasket (28).
4. On pumps built without a valve plate, lubricate
Inspection the end cap prior to installation.
1. Inspect the end cap (25) and/or valve plate (29) 5 Install end cap (25). Before installing the four
for damage, nicks or unusual wear patterns. end cap bolts (58), push down on the end cap
(25) verifying alignment and insuring that the
Install end cap bolts. Tighten, per Table 2, page
110, torque values.
Prior to Serial # 0216Pxxxxx On or After Serial # 0216Pxxxxx

15
15
26
26
29
26
26
28
28
(4X) 58 25 25
(4X) 58
Figure 11. PW Pump End Cap
118 PW Series
Assembly
Refer to Figure 12. 3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
Disassembly
1. Tilt the pump on its side, drain remaining oil. Lift the cylinder block assembly (38) with pistons
out the cylinder block assembly (38). contacting the thrust bearing.

NOTE: To check that piston placement is
Inspection
correct, push downward on the cylinder
1. Inspect the running surface of the cylinder block block assembly (38). If this results in a
and piston ends for damage, nicks or unusual spring action the block assembly has
wear patterns. been installed correctly. If this cannot be
accomplished, remove and reassemble
minor abrasion. This will be normal wear. If
the block assembly. Place a rubber band
grooved or smeared, replace with a new cylinder around the cylinder block pistons to hold
block assembly. them in position during installation. Then
after installation cut the rubber band and
2. Inspect the piston springs for distortion or remove it. Check for cylinder block as-
breakage. If necessary, replace with a new sembly for spring action.
cylinder block kit.
3. Inspect the piston seats. Residual oil may

pistons.
Piston (7X)
Spring (7X)
Piston
Seat (7X)
Cylinder Block
38
Figure 12. PW Pump Cylinder Block
PW Series 119
ASSEMBLY OF THRUST BEARING ASSEMBLY OF SWASHPLATE AND
Refer to Figure 13. CRADLE BEARINGS
Disassembly Refer to Figure 14.
1. Remove the thrust bearing and race (17). Disassembly
Inspection 1. Remove the swashplate (31).
1. Inspect the running surface of the bearing race Inspection

for damage (17), nicks or unusual wear patterns.
for damage (31), nicks or unusual wear patterns.
minor abrasion. This will be normal wear.
Inspect the bearings for free movement. Inspect
minor abrasion. This is normal wear. Inspect
the cradle bearing side of the swashplate (31)
for damage. Replace if necessary.
Assembly
1. Install thrust bearing and race assembly (17). of the housing (15) for normal wear patterns,
placement, and insure they are staked in place.
If damaged, replace housing (15).
NOTE: The difference in race thickness-
es: The thin race seats into the swash-
plate. The thicker race will be installed NOTE: The cradle bearings will have
toward the piston noses. discoloration due to normal wear. Under
rant replacement.
Assembly

(13) slot guide (14) with a flat tip screwdriver.
Use the screwdriver to hold the slot guide (14)
in place while positioning the swashplate (31)
onto the cradle bearing in the housing (15).
17 2. Rotate trunnion arm (13) to assure swashplate

pivoting action.
Figure 13. PW Pump Thrust Bearing
13
14
31
17 15
(Cradle Bearings cannot be

Figure 14. PW Pump Swashplate and

Cradle Bearings
120 PW Series
bly.
Refer to Figure 15.
5. Inspect and replace the thrust spring (20)
Disassembly
1. Remove the retaining ring (3). broken.
Assembly
2. Remove the lip seal (6).
3. Remove the spacer (4). that all seals, O-rings and gaskets be re-
4. Remove the shaft assembly (1).
Inspection clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
damage, or keyway damage. Replace shaft
assembly if necessary.
1. Install input shaft (1) assembly into the housing
2. Inspect the bearing (5) for evidence of scoring, (15) bore. Light tapping with a rubber mallet
corrosion, or damage. Replace shaft assembly may be necessary on the input shaft (1) once
if necessary. the bearing is aligned with the housing bore
(15). Rotate the input shaft (1) to insure free
3. Inspect and replace the spacer (4) if it is bent or movement.
broken.
after removal. 3. Install new lip seal (6). Remove the plastic
wrap.
4. Inspect and replace the retaining ring (3) if it is 4. Install retaining ring (3).
bent or broken.
3
6
5
4
2
19
15 20
Figure 15. PW Pump Input Shaft
PW Series 121
REMOVAL AND INSPECTION OF
TRUNNION ARM
Refer to Figure 16.
15
Disassembly 12
1. Remove trunnion seal retainer and seal (12).
Inspection

Assembly 14
1. Install the trunnion arm (13) into the housing

13
movement.
Figure 16. PW Pump Trunnion Arm
that all seals, O-rings, and gaskets be re-
Remove the plastic wrap after the seal
is installed.
2. Install a new seal and seal retainer.
3. Install the slot guide (14).

manual.
122 PW Series
PW Series 123
124
Figure 17. PW Pump
85- Overhaul Seal Kit
Kit Number
PW Series
ITEM LIST - PW SERIES

1 Pump Shaft Kit (19T spline) Charge pump Kit (AL Aux, 7/16 SAE port,
Pump Shaft Kit (closed key) 75-105 psi)
Pump Shaft Kit (thru shaft spline) 41 Gerotor Assembly (0.19 in3/rev)
Pump Shaft Kit (tapered thru shaft) Aux Gerotor & HSG Assembly (0.19 in3/rev)
Pump Shaft Kit (shaft - thru pump) Gerotor Assembly (0.13 in3/rev)
Retaining Ring 42 Check Valve Kit (.031)
4 Spacer Check Valve Kit (.044)
5 Shaft Ball Bearing Shock Valve Kit (blank)
6 Lip Seal 17 X 47 X 8 PTCN1 System Check/Relief Kit
10 Trunnion Seal Retaining Ring 44 Charge Relief Kit (w 1/2 SAE valve plug,
12 Lip Seal 15 X 27 X 7 40-70 psi)
13 Trunnion Arm Charge Relief Kit (w 1/2 SAE valve plug,
14 Slot Guide 135-165 psi)
15 Housing Kit Charge Relief Kit (w/ 9/16 SAE valve plug)
17 Thrust Ball Bearing Assembly Charge Relief Kit (w/ 9/16 SAE valve plug
19 Block Thrust Washer 75-105 psi)
20 Block Spring Charge Relief Kit (w/ 7/32 plastic ball &
25 End Cap Kit (w/poppets) spring)
End Cap Kit (w/poppets , .078 cooling ori Charge Relief Kit (w/ 1/4 plastic ball &
fice) spring)
End Cap Kit (w SCRS) 45 Aux Relief Valve Kit
End Cap Kit (Aux w/ poppets) 49 Aux Bypass/Check Kit
End Cap Kit (Aux w/ SCRs) 50 Bypass Valve Kit (blank)
End Cap Kit (Aux w/ LH:SCR and Bypass Valve Kit (.031)
RH:poppet) 54 Auxiliary Filter Kit
End Cap Kit (w/LH:poppet and RH:SCR) 56 Hex Screw, 5/16 - 18 X 1.0
26 Pin Hex Hd Cap Screw, 5/16 - 18 X 2.5
28 O-Ring 58 Hex Screw, Flanged Head
29 Valve Plate 59 Hex Flange Nut
31 Variable Swashplate 60 Mounting Bracket
38 Cylinder Block Kit 66 Plug
R-Ring (-144) 69 Pin
40 Charge Pump Kit (0.19 std splined) 85 Overhaul Seal Kit
Charge Pump Kit (0.13 std splined) 110 Return Kit
Charge Pump Kit (0.13 std thru shaft) 168 Connector
Charge Pump Kit (0.13 std spline, 209 Shroud Bracket
clear zinc cover) 210 Shroud
Charge Pump Kit (CW - splined Aux, 40-70
psi)
Charge Pump Kit (CW - splined Aux,
135-165 psi)
Charge Pump Kit (CCW - splined Aux, 40-70
psi)
Charge Pump Kit (AL Aux, 7/16 SAE port,
40-70 psi)
PW Series 125
126 PW Series
GLOSSARY OF TERMS
Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged
parallel with the spindle (input or output shaft).
Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor
or pump. Also referred to occasionally as the freewheel valve or dump valve.
Case Drain Line (Return Line): A line returning fluid from the component housing to the reser-
voir.
Cavitation: A phenomenon of boiling in a flowing liquid at normal temperatures, as a result of low

pressure condition. The gas liberated from the fluid implodes rapidly and damages pump compo-
nents.
Center Section: A device which acts as the valve body and manifold of the transmission.
Charge Pump: A device which supplies replenishing fluid to the fluid power system (closed
loop).
Charge Pressure: The pressure at which replenishing fluid is forced into a fluid power system.
Charge Relief Valve: A pressure control valve whose primary function is to limit pressure in the
charge circuit.
Check Valve: A valve whose primary function is to restrict flow in one direction.
Closed Loop: A sealed and uninterrupted circulating path for fluid flow from the pump to the
motor and back.
Decay Rate: The ratio of pressure decay over time.
End Cap: See Center Section.
Entrained Air: A mechanically generated mixture of air bubbles having a tendency to separate
from the liquid phase.
Gerotor: A fixed displacement pump frequently used as a charge pump.
Hydraulic Motor: A device which converts hydraulic fluid pressure and flow into mechanical
force and motion.
Hydraulic Pump: A device which converts mechanical force and motion into hydraulic fluid pres-
sure and flow.
Hydrostatic Motor: See Hydraulic Motor.
Hydrostatic Pump: See Hydraulic Pump.
Hydrostatic Transaxle: A multicomponent assembly including a gear case and a hydrostatic

transmission.
P Series 127
Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to
form a device for the control and transfer of power.
Inlet Line: A supply line to the pump.
Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission and

gear case in one housing to form a complete transaxle.
Manifold: A conductor which provides multiple connection ports.
Neutral: Typically described as a condition in which fluid flow and system pressure are below
that which is required to turn the output shaft of the motor.
Pressure Decay: A falling pressure.
Priming: The filling of the charge circuit and closed loop of the fluid power system during
start-up, frequently achieved by pressurizing the fluid in the inlet line.
Purging: The act of replacing air with fluid in a fluid power system.
Rated Flow: The maximum flow that the pump is capable of supplying.
Scoring: Scratches in the direction of motion of mechanical parts caused by abrasive contami-
nants.
Shock Valve: A relief valve in the closed loop of the hydrostatic circuit that provides makeup oil,
as well as protecting the circuit from high pressure shocks or spikes.
Swashplate: A mechanical device used to control the displacement of the pump pistons in a fluid
power system.
System Charge Check Valve: A valve controlling the replenishing flow of fluid from a charge
circuit to the closed loop in a fluid power system.
System Pressure: The pressure which overcomes the total resistance in a system, including all
efficiency losses.
Valve: A device which controls fluid flow direction, pressure, or flow rate.
Variable Displacement Pump: A pump in which the displacement per revolution can be varied.
Volumetric Displacement: The fluid volume for one revolution.
128 P Series
2010 HYDRO-GEAR
Printed in U.S.A.
Rev. P3

P Series Hydrostatic Pumps Service and Repair Manual: PW PK

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

P Series Hydrostatic Pumps Service and Repair Manual: PW PK

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

P Series Hydrostatic Pumps Service and Repair Manual: PW PK

Uploaded by

Copyright:

Available Formats

PK

Service and Maintenance............................................................................................. 18-20

Glossary of Terms..................................................................................................... 127-128

Reversing the direction of the angle of the swash-

A fixed displacement gerotor charge pump is

Check or shock valves are included in the pump end

Figure 1. PC Pump with Standard Charge Pump

STANDARD CHECK CHARGE TRUNNION

Figure 2. PG Pump With Standard Charge Pump

Figure 3. PJ Pump with Standard Charge Pump

Figure 4. PK Pump With Standard Charge Pump

INPUT SHAFT INLET

SYSTEM CHECK VALVE SYSTEM CHECK VALVE

Figure 4. PR Pump With Standard Charge Pump

BYPASS VALVE CASE DRAIN

STANDARD CHECK VALVE CHARGE STANDARD CHECK VALVE

Figure 5. PW Pump With Standard Charge Pump

System Check & Relief Valve Options

System Check & Relief Valve Options

No Bleed Check ball Check ball

Figure 7. PC, PG, PJ, PK and PR Pumps with AuxiliaryCharge Pump

No Bleed Check ball Check ball

Figure 8. PW Series Pump With Standard Charge Pump

System Check & Relief Valve Options

No Bleed Check ball Check ball

Figure 9. PW Series Pump With Auxiliary Charge Pump

Figure 10. P Series Pump With Standard Charge Pump

Displacement in3/rev 0.37 0.62 0.73 0.97 1.33

System Operating Pressure

Charge Pump Displacement(s)

Auxiliary Pump Displacement

Auxiliary Pump Relief Setting

Auxiliary Pump Performance

Control Torque Required to Stroke Pump

Pump Oil Temperature

Fluid Viscosity Limits @ 230F [110C]

Inlet Filtration Requirement

Table 1: P Series Pump Technical Specifications

4 244 P1 0192 MADE IN U.S.A.

type of Product and Build Information

Figure 11. P Series Pump Configuration Label

Inspect each tool before use and replace any tool

Never allow untrained or unauthorized personnel to

In many cases, problems with the P Series Pump

VEHICLE DOES NOT DRIVE/TRACK STRAIGHT

Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure

Bypass loose Tighten pump bypass per External Maintenance

Inlet Leak Check all external lines and connections to pump

Excessive loading Reduce vehicle load

Bypass loose Tighten pump bypass per External Maintenance

Table 2. Pump Troubleshooting Checklist

UNIT HAS NO/LOW POWER

Engine speed low Adjust to correct rpm setting

Excessive loading Reduce vehicle load

Bypass loose Tighten pump bypass per External Maintenance

Inlet leak Check all external lines and connections to pump

Inlet filter clogged Replace inlet filter