Removal and Installation of Pump

Removal and Installation of Hydraulic Pump

Warning ・ Be sure to release hydraulic pressure before beginning work.

Caution ・ Be sure to stop the engine before beginning work. ・ Be sure to inspect the wire rope and other lifting equipment before beginning work. ・ Do not stand or pass under the suspended load.

Items to prepare •Wrenches (13 mm, 14 mm, 17 mm, 19 mm, 22 mm, 30 mm, 36 mm) •Hexagon wrenches (8 mm, 10 mm) •Nylon sling (with the required breaking load) •Crane (with the required lifting capacity) •Marking pen •Caps •Plugs •Rag •Cleaning fluid •Wood planks, etc. 1.Removal of Hydraulic Pump [1] Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the under cover (2).

[2] Remove the engine hood.

For procedure, see "Removal and Installation of Engine Hood".

[3] Use a wrench (19 mm) to remove the 4 bolts (3) from the top cover.

1 Bolt 2 Under cover 3 Bolt

[4] Use a wrench (13 mm) to remove the 2 bolts (3), and then remove the torsion bar bracket (4) for the engine hood.

[5] Use a wrench (19 mm) to remove the 4 bolts (5) from the inside of the top cover.

[6] Remove the top cover (6).

3 Bolt 4 Torsion bar bracket 5 Bolt 6 Cover

[7] Use a wrench (19 mm) to remove the 9 bolts (7), and then remove the 4 covers (8), (9), (10), and (11).

[8] Use a wrench (14 mm) to remove the 2 bolts (12) and 2 nuts (13), and then remove the exhaust pipe seal clamp (14).

[9] Use a wrench (17 mm) to remove the 3 bolts (15), and then remove the muffler installation bracket (16).

7 Bolt 8 Cover 9 Cover 10 Cover 11 Cover 12 Bolt 13 Nut 14 Seal clamp 15 Bolt 16 Muffler bracket

[10]Remove the muffler (17).

[11]Remove the hoses and connectors that are connected to the pump.

Use a hexagon wrench (8 mm) to remove the 8 hose bolts (18), and remove the pressure hoses (19).

Use a wrench (36 mm) to remove the drain hose (20).

Use a wrench (22 mm) to remove the pilot hose (21).

Use a wrench (30 mm) to remove the suction hoses (24) and (25).

Remove the connectors (23).

Use a wrench (19 mm) to remove the pilot hoses (22) and (25).

Remove the connectors (26).

Use a hexagon wrench (10 mm) to remove the suction line bolts (27) (2 in front, 2 in back), and remove the suction line (28). •Mark the pump and hoses so that the connectors match at the time of assembly. •Attach caps or plugs to the pump and hoses to prevent any entry of water, dust or dirt. •Clean the pump and hoses by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

17 Muffler 18 Bolt 19 Pressure hose 20 Drain hose 21 Pilot hose 22 Pilot hose 23 Connector 24 Pilot suction hose 25 Pilot hose 26 Connector 27 Bolt 28 Suction line

[12]Secure the pump with a crane and nylon sling (29) so that it does not fall during removal and installation operations.

[13]Use a wrench (17 mm) to remove the 9 bolts (30) from the pump.

[14]Use a crane and the nylon sling (29) to pull the pump out from the shaft and lift the pump.

29 Nylon sling 30 Bolt

[15]Thoroughly check that the location is safe before lowering the pump on wood planks (31). •Thoroughly secure the pump so that it does not fall over.

2.Installation of Hydraulic Pump

Perform the reverse of the removal procedure.

The tightening torque for the pump bolt (1) is 63.7 - 72.6 N•m.

Fill the pump case with hydraulic oil from the drain port so that no air remains in the pump case.

Additionally, when there is a 2nd option gear pump, bleed off air from the air bleed port on the top surface of the power take-off case.

31 Wood plank

1 Bolt