Required Tools

Tool Part Number Part Description Qty

A 1P-2420 Transmission Repair Stand 1

B 138-7575 Link Bracket 2

C 138-7573 Link Bracket 2

D 1U-8758 Retaining Ring Pliers 1

E 141-4803 Gauge Block Set 1

F 8T-5096 Dial Indicator Test Group 1

149-4935 Measuring Tool Group 1

G
187-6278 Gauge Plate 2

H 1P-1859 Retaining Ring Pliers 1

1U-5823 Driver 1
J
5P-4197 Spacer 1

NOTICE
Keep all parts clean from contaminants.
Contamination of the hydraulic system with foreign material
will reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system,
always plug or cap the lines, fittings, or hoses as they are
disconnected. Cover any disassembled components and clean
them properly before assembly.
Clean the hydraulic system properly after any major
component exchange or especially after a component failure, to
remove any contamination.

Note: If a failure occurs, an accurate diagnosis of the cause can prevent a recurrence. Information is available to analyze
failures for piston pumps and motors. Refer to Special Publication, SEBD0641, "Analyzing Axial Piston Pump and Motor
Failures".

Note: Inspect all parts. If any parts are worn or damaged use new parts for replacement. The installation of used parts during
reconditioning is acceptable. Reuse and salvage information is available on piston pumps. Refer to Guideline For Reusable
Parts and Salvage Operations, SEBF8032, "Piston Pumps and Motors". During reconditioning, correct any conditions that might
have caused the original failure.

Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a
new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.

Note: Apply a light film of "10W" oil to all components before assembly.

1. Assemble the pump control. Refer to Disassembly and Assembly, "Pump Control - Assemble" in this manual.

Assembly Procedure for the Upper Pump Rotating

Group
Illustration 1 g00681108

Cross section view of the upper pump rotating group.

(A) Dimension that is determined by shim (41)

(37) Snap ring

(38) Bearing assembly

(39) Bearing assembly

(40) Plate
(41) Shim
 Illustration 2 g00681724

Cross section view of bearing assembly (39) .

(39a) Bearing cone

(39b) Spacer
(39c) Bearing cup
(39d) Bearing spacer
(39e) Bearing cone

(39f) Bearing cup

1. Perform the stackup of bearing assembly (39) for the lower pump rotating group, as follows.
 Illustration 3 g00632629
2. Position gauge blocks from Tooling (E) on a surface plate in order to obtain dimension (A) of 86.5 mm (3.41 inch).
3. Position Tooling (F) over the gauge blocks, and zero the indicator.
 Illustration 4 g00632637

Measurement that determines the thickness of shim (41)

(41) Shim

(39) Bearing Assembly

4. Slide the bearing assembly under Tooling (F) .

5. The indicator should indicate between 0.00 mm (0.000 inch) and -0.10 mm (-0.004 inch) for the correct dimension (A) .

Table 2

Table for Shim (41) (1)

Shim Thickness (mm)

177-2513 6.2

177-2514 6.3

177-2515 6.4

177-2516 6.5

177-2517 6.6
(1)

Use the necessary shim (41) for adjusting dimension (A) for the upper
 pump rotating group.
6. Add shims (41) in order to obtain the correct dimension (A) .
Note: Use only one shim in order to obtain the stackup of bearing (39) . The stackup of bearing assembly (39) determines
the position of the rotating group inside the main pump housing/">housing.

7. The following Steps 8 through 15 are for the buildup of bearing assembly (39) .

Illustration 5 g00640449
8. Heat bearing cone (39a) to the maximum temperature of 100 C (212 F).
9. Install bearing cone (39a) onto the shaft.

Illustration 6 g00641138
10. Install spacer (39b) .
 Illustration 7 g00640454
11. Install bearing cup (39c) .

Illustration 8 g00640654
12. Install bearing spacer (39d) .

Illustration 9 g00640658
13. Heat bearing cone (39e) to the maximum temperature100 C (212 F).
14. Install bearing cone (39e) on the shaft.

Illustration 10 g00640665
15. Install bearing cup (39f) onto the shaft. This is the final component for bearing assembly (39) .

Illustration 11 g00640668
16. Install shim (41) onto the shaft.
17. Steps 18 and 19 are the components that make up bearing assembly (38) .
 Illustration 12 g00640671
18. Install bearing cup (38a) .

Illustration 13 g00640676
19. Heat bearing cone (38b) to the maximum temperature of 100 C (212 F).
20. Install bearing cone (38b) .
 Illustration 14 g00641131
21. Install plate (40) .

Illustration 15 g00641129
22. Use Tooling (G) in order to install retaining ring (37) .

Assembly Procedure for the Lower Pump Rotating

Group

Illustration 16 g00681036

Cross section view of the lower pump rotating group.

(A) Dimension that is determined by shim (36)
(32) Snap ring
(33) Bearing assembly

(34) Bearing assembly

(35) Plate
(36) Shim

Illustration 17 g00682774

Cross section view of bearing assembly (34) .

(34a) Bearing cone
(34b) Spacer
 (34c) Bearing cup

(34d) Bearing spacer

(34e) Bearing cone
(34f) Bearing cup

1. Perform the stackup of bearing assembly (34) for the lower pump rotating group, as follows.

Illustration 18 g00632629
2. Position gauge blocks from Tooling (E) on a surface plate in order to obtain dimension (A) of 86.5 mm (3.41 inch).
3. Position Tooling (F) over the gauge blocks, and zero the indicator.
 Illustration 19 g00685169

Measurement that determines the thickness of shim (36)

(36) Shim

(34) Bearing Assembly

4. Slide the bearing assembly under Tooling (F) .

5. The indicator should indicate between 0.00 mm (0.000 inch) and -0.10 mm (-0.004 inch) for the correct dimension (A) .

Table 3

Table for Shim (36) (1)

Shim Thickness (mm)

177-2487 3.3

177-2488 3.4

177-2489 3.5
(1)

Use the necessary shim (36) for adjusting dimension (A) for the lower
pump rotating group.
6. Add shims (36) in order to obtain the correct dimension (A) .
Note: Use only one shim in order to obtain the stackup of bearing assembly (34) . The stackup of bearing assembly (34)
determines the position of the rotating group inside the main pump housing/">housing.
7. The following Steps 8 through 15 are for the buildup of bearing assembly (34) .

Illustration 20 g00640332
8. Heat bearing cone (34a) to the maximum temperature of 100 C (212 F).
9. Install bearing cone (34a) .

Illustration 21 g00682051
10. Install bearing spacer (34b) .
 Illustration 22 g00640334
11. Install bearing cup (34c) .

Illustration 23 g00640335
12. Install bearing cup (34d) .

Illustration 24 g00640336
13. Heat bearing cone (34e) to 100 C (212 F).
14. Install bearing cone (34e) .

Illustration 25 g00640397
15. Install bearing cup (34f) . This is the final component for bearing assembly (34) .

Illustration 26 g00640402
16. Install shim (36) .
17. Steps 18 and 19 are the components that make up bearing assembly (33) .
 Illustration 27 g00640405
18. Install bearing cup (33a) .

Illustration 28 g00640407
19. Heat bearing cone (33b) to the maximum temperature of 100 C (212 F).
20. Install bearing cone (33b) .

Setting the Bearing Preload

Illustration 29 g00682033

Upper Pump Rotating Group

(B) Dimension that is determined by spacer (8)

(40) Plates that determine bearing preload

 Illustration 30 g00683202

Lower Pump Rotating Group

(B) Dimension that is determined by spacer (8)

(35) Plates that determine bearing preload

1. After the pump rotating groups have been assembled you must perform two primary procedures. Complete the following
procedures: Bearing preload and Lift-off Limitation.
Note: The bearing preload procedure that follows pertains only to new bearings with manufacture's lubricant.
 Illustration 31 g00682451
Note: Setting the bearing preload of the rotating group will require the use of bearing support (K) .

2. To fabricate bearing support (K) , cut a 90 degree vee approximately 150 mm (5.9 inch) wide into a block of wood. Call this
dimension (C) .
3. This wood block will be used to hold the rotating group while the drive shaft is rotated.
4. The following plates are used to adjust the bearing preload.

Table 4

Table for Plate (35) and (40) (1)

Plate Thickness (mm)

177-2491 2.6

177-2492 2.65

177-2493 2.70

177-2494 2.75

177-2495 2.80

177-2496 2.85

177-2497 2.90

177-2498 2.95
(1)

Use the necessary plates (35) and (40) for adjusting the bearing preload
on both rotating groups.
 Illustration 32 g00681982
5. Place the upper rotating group onto bearing support (K) .
6. In order to check bearing preload, turn the M10 X 1.5THD bolt in the center of the upper rotating pump group with a dial
type torque wrench.
Rolling torque ... 3.75 0.25 Nm (33.190 2.213 lb in)

Illustration 33 g00682002
7. Place the lower rotating group onto bearing support (K) .
8. In order to check bearing preload, turn the M16 X 2.00THD bolt in the center of the upper rotating pump group with a dial
type torque wrench.
Rolling torque ... 3.75 0.25 Nm (33.190 2.213 lb in)

Adjustment for Lift-Off Limitation (Cylinder Barrel To

Port Plate for Maximum Separation)
ReferenceRefer to Tool Operating Manual, NEHS0699-01 for completing this procedure.
 Illustration 34 g00907038
1. Align the timing marks on the rotating groups. The timing marks are at position (Z) .

Illustration 35 g00526328
2. Heat the main pump housing to a temperature of 80 C (176 F). Install the upper pump rotating group and the lower pump
rotating group in both of the pump rotating group's original locations in the main pump housing/">housing.
3. Make sure that the timing marks on each pump rotating group are in alignment with each other, as shown.
 Illustration 36 g00682500
4. Install both retaining plates (12) and centering pins (13) .

Illustration 37 g00682571
5. Tighten socket head screws (11) to a torque of 12 3 Nm (9 2 lb ft).
6. Tooling (G) has several gauge plates. Select 187-6278 gauge plate for the pump.

Illustration 38 g00682512
7. Install three lead balls into the gauge plate, as shown.
8. Make sure that the lead ball is inserted into the large holes on the gauge plate. To keep the lead balls from falling out of
the gauge plate during installation, press on each lead ball with your thumb.
Note: Do not crush the lead balls. Pressing the balls too deeply into the gauge plate will provide inaccurate
measurements.
 Illustration 39 g00682521
9. Place the gauge plate and the three lead balls on the centering pin (13) .

Illustration 40 g00682536
10. Carefully place cylinder barrel (7) over the gauge plate and centering pin (13) .
Note: Do not drop the cylinder barrel onto the centering pin. Dropping the cylinder barrel will prematurely crush the lead
balls. This will cause inaccurate measurements.
 Illustration 41 g00682537
11. Place cylinder barrel (7) over the gauge plate and centering pin (13) .

Illustration 42 g00682542

(S) Suction side

12. Apply petroleum jelly under both port plates (6) .

13. Place each port plate (6) into position on the pump control, as shown.

Illustration 43 g00689163
14. Install gasket (10) on the main pump housing/">housing.
 Illustration 44 g00633590
15. Fasten Tooling (B) and a hoist to the pump control (4) .
16. Carefully install the pump control (4) on top of the main pump housing/">housing.
Note: If the pump control comes down hard onto the port plates, you should remove the pump control. Then, verify that
you have not damaged the lead balls. If the lead balls are damaged, you should replace the lead balls. Then, reinstall the
pump control.

17. Torque bolts (3) to 240 40 Nm (175 30 lb ft), while you turn the pump shaft.
18. Loosen and remove the previously installed socket head bolts (3) .

Illustration 45 g00633590
19. Use Tooling (B) and a hoist in order to remove the pump control (4) .
 Illustration 46 g00682537
20. Remove the cylinder barrels (7) .
21. Remove the gauge plate (G) with the lead balls.
22. Determine the lift-off dimension, as follows.

Illustration 47 g00682628
23. Measure all three lead balls and write down the average of the three. Call this Dimension (Z) .
Note: Keep each gauge plate with the respective rotating groups because you will have different lift-off dimensions for
each rotating group.

24. Use the following equation to determine the Lift-Off Limitation:

(Z) - 0.40 0.10 mm (0.016 0.004 inch)

25. Dimension (B) should equal the thickness of one of the spacers (8) .

Table 5

Table for Spacer (8) (1)

Spacer Thickness (mm)

177-2509 12.3

177-2508 12.4
 177-2507 12.5

177-2506 12.6

177-2505 12.7

177-2504 12.8
(1)

Use the necessary spacer (8) for setting the lift-off limitation for the upper
pump rotating group and the lower pump rotating group.
27. ReferenceRefer to Illustrations 29 and 30 for dimension (B) .

26. Make sure that you do not interchange the spacers, because the pump could be damaged beyond repair.

Illustration 48 g00682571
27. Remove socket head screws (11) that hold the retaining plate and the centering pin.

Illustration 49 g00682500
28. Remove both retaining plates (12) and centering pins (13) .
29. Turn the main housing over 180 degrees.
 Illustration 50 g00640775
30. Install plug (19) .

Illustration 51 g00684424
31. Install bearing (31) in the bearing's original position in the main pump housing/">housing. The bearing is a slip fit.

Illustration 52 g00681619
32. Use a hammer in order to install key (29) into shaft (28) .
33. Heat gear (30) to a maximum temperature of 85 C (185 F).
34. Lower the temperature of shaft (28) to -40 C (-40 F).
35. Place the preheated gear in the main pump housing above bearing (27) .

Illustration 53 g00681714
36. Install the cooled shaft through gear (30) and into bearing (31) .
Note: Make sure that you align the woodruff key in shaft (28) with the corresponding slot in gear (30) .

37. Install bearing (27) on the shaft. Bearing (27) is a slip fit on the shaft.

Illustration 54 g00640813
38. Install three O-ring seals (26) to the pilot pump.
 Illustration 55 g00640803
39. Place pilot pump (24) in position in the main pump housing/">housing.
40. Install two bolts (25) that hold the pilot pump in position.

Illustration 56 g00681785

Illustration 57 g00684295
41. Position lip type seal (23) inside the main pump housing/">housing.
 Note: Use Tooling (J) to install the lip type seal (23) into the bore of the main housing/">housing. Drive the seal slightly
past the retaining ring groove in the main pump housing/">housing.

42. Make sure that the sealing lip is facing toward the inside of the main pump housing/">housing.

Illustration 58 g00640793
43. Install shim (22) .

Illustration 59 g00640789
44. Use Tooling (D) and install retaining ring (21) .
45. Turn the main pump housing over 180 degrees.
 Illustration 60 g00634154
46. Install two rings (16) on each piston (15) .

Illustration 61 g00634149
47. Install pistons (14) in the piston's original locations in the pump rotating groups.

Illustration 62 g00634146
48. Install retaining plates (12) and centering pins (13) in the original positions over the pistons. Make sure that the screw
holes in the retaining plates are in alignment with the screw holes in the pump rotating groups.

Illustration 63 g00634140
49. Apply 9S-3263 Thread Lock Compound on the threads of socket head screws (11) .
50. Install the socket head screws in order to hold retaining plates (12) to the pump rotating groups. Tighten the socket head
screws evenly.
51. Install gasket (10) .

Illustration 64 g00634134
Note: Bevel spring washers (9) are not flat. These washers should be installed so that the washers provide the maximum
amount of height.

52. Install spacer (8) and four bevel spring washers (9) in each cylinder barrel (7) .
Note: Use the spacer that was determined in Steps 2 through 26.
 Illustration 65 g00684444

(7) Cylinder barrel

(8) Spacer

(9) Bevel washers

53. Install the bevel spring washers, as shown.

Note: Apply petroleum jelly to bevel spring washers (9) and spacer (8) in order to prevent bevel spring washers (9) and
spacer (8) from falling out of barrel (7) during installation.
 Illustration 66 g00633605
54. Install two cylinder barrels (7) in the cylinder barrel's original locations on the pump rotating groups.

Illustration 67 g00685317
55. Install two dowels (5) in the main pump housing/">housing.

Illustration 68 g00682542

(S) Suction side

56. Apply petroleum jelly under both port plates (6) .

57. Place each port plate (6) into position on the pump control, as shown.
 Illustration 69 g00633590
58. Fasten Tool (B) and a hoist to pump control (4) , as shown. Place the pump control in position on the main hydraulic pump.
59. Install socket head bolts (3) that hold the pump control to the main hydraulic pump.

Illustration 70 g00633959
60. Install the O-ring and plate (2) on the main pump housing/">housing.
61. Install the four socket head bolts that hold the plate in position.
62. Make sure that drain plug (1) is tight.
Note: Bench test the pump. Refer to Special Instruction, NEHT5000, "Bench Testing Hydraulic Components" for the
correct procedure to bench test the main hydraulic pump.

End By: Install the main hydraulic pump and the pump drive coupling. Refer to Disassembly and Assembly, "Main Hydraulic
Pump and Pump Drive Coupling - Install" in this manual.