SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 4 - Hydraulic pump

CONTENTS
Section 82021 Description Page
Specifications ................................................................................................. 1
Torque specifications .................................................................................... 1
Description ..................................................................................................... 2
Disassembly ................................................................................................... 3
Reconditioning and replacement of parts ................................................... 8
Assembly ...................................................................................................... 14
Inspection and adjustments ........................................................................ 26

SPECIFICATIONS

Pump 90R042PV Pump 90R055PV Pump 90R075PV

SV212 (vibration) SV208 (travel) SV212 (travel)
Machine (location) SV210 (travel) SV216 (travel)
SV216 (vibration)
Displacement (maximum) 42 cm3 (2.56 in3) 55 cm3 (3.35 in3) 75 cm (4.57 in3)
Minimum speed 500 rpm 500 rpm 500 rpm
0.67 Nm/bar 0.88 Nm/bar 1.19 Nm/bar
Theoretical torque at max. disp.
(0.3 lb ft/psi) (0.5 lb ft/psi) (0.7 lb ft/psi)
Weight 37 kg (75 Ib) 40 kg (88 Ib) 49 kg (108 Ib)

! WARNING ! 1
Be sure to fill the pump housing with clean hydraulic
fluid prior to start up. Fill the housing by pouring fil-
tered oil into the upper case drain port (1).

CS01D530 1

TORQUE SPECIFICATIONS
90R042PV 90R055PV 90R075PV
Swashplate .......................................................13.5 Nm (9.96 Ib.ft)...... 13.5 Nm (9.96 Ib.ft) ...... 13.5 Nm (9.96 Ib.ft)
Servo-cylinder........................................................9 Nm (6.63 Ib.ft)...... 13.5 Nm (9.96 Ib.ft) ........ 24 Nm (17.7 Ibf.ft)
Leveler guide ..........................................................23 Nm (17 Ib.ft)............ 23 Nm (17 Ib.ft) ............ 23 Nm (17 Ib.ft)
Side cover.........................................................13.5 Nm (9.96 Ib.ft)......... 32.5 Nm (24 Ib.ft) ......... 32.5 Nm (24 Ib.ft)
Swashplate guide .............................................13.5 Nm (9.96 Ib.ft)......... 32 Nm (23.6 Ib.ft) ......... 32 Nm (23.6 Ib.ft)
Side cover screws installed in “Blind” holes .....13.5 Nm (9.96 Ib.ft)......... 32.5 Nm (24 Ib.ft) ......... 32.5 Nm (24 Ib.ft)
Side cover screws installed in “Thru” holes........10.5 Nm (7.7 Ib.ft)......... 25 Nm (18.4 Ib.ft) ......... 25 Nm (18.4 Ib.ft)

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2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

DESCRIPTION

25 26 23 22 49
21

24
15 48
17 47 38
37 39

33 34 30 31
31
17 40
18
36
17 35 35
32 34
33
14 28
16
46
13 41

12 27 29 45

19 44 42
20 11
9
8 43
5 6
2 3 10 50 51 52
7
1
4
CS01D586 2
1. Cover 22. Piston 43. Plug
2. Bolt 23. Slipper guide 44. Spring
3. O-ring 24. Guide 45. O-ring
4. Bolt 25. Bolt 46. Pin
5. Adapter 26. Spacer 47. Gasket
6. O-ring 27. Swashplate 48. Adapter plate
7. Plate 28. Leveler, complete 49. Solenoid
8. Spacer 29. Bearing 50. Orifice plate
9. Spacer 30. Piston 51. Spring
10. O-ring 31. Plug 52. Spring retainer cup
11. Coupling 32. Housing
12. Plug 33. Bolt
13. Relief valve 34. O-ring
14. Relief valve 35. O-ring
15. Adjusting screw 36. Shaft
16. Screw 37. Bearing
17. Plug 38. Plate
18. Screw 39. Shaft packing
19. Gasket 40. O-ring
20. End cover 41. Swashplate leveler
21. Cylinder block 42. Cover

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 3

DISASSEMBLY
90R055PV PUMP
1. Thoroughly clean all external surfaces prior to
removal of the control components.
2. Using a 4 mm internal hex wrench, remove the four
electro-valve mounting screws. Remove the elec-
tro-valve (with O-rings and orifice) from the adapter
plate.
3. Using a 5 mm internal hex wrench, remove the
eight adapter plate mounting screws. Remove the
adapter plate and gasket from the housing.

! WARNING !
Protect exposed surfaces and cavities from dam-
age and foreign material.

4. Inspect the orifice installed between the valve and CD01D134 3

adapter plate. This orifice must be installed in the
case drain passage for proper pressure limiter
operation.
90R042PV OR 90R075PV PUMPS
5. Thoroughly clean the external surfaces of the con-
trol components.
6. Using a 4 mm internal hex wrench, remove the four
screws and remove the pressure-control-pilot.
7. Check all surfaces for nicks or damage. Clean the
internal screens.

CD01D135 4
8. Thoroughly clean all external surfaces prior to
removal of the control components.
9. Using a 5 mm internal hex wrench, remove the
eight control mounting screws. Remove the control
assembly (with orifice check valve and spring) and
control gasket from housing.

! WARNING !
Protect exposed surfaces and cavities from dam-
age and foreign material.

CD01D136 5

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4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

10. Remove the multi-function valve cartridge with a

32 mm hex wrench on the largest hex on the car-
tridge.

CD01D137 6
11. Remove the shim adjustable pressure relief valve
plug with a 25 mm hex wrench.
12. Position the pump with the shaft facing up.

CD01D138 7
13. Remove the three or four screws holding the
retainer plate and seal carrier to the housing using
a 10 mm hex wrench (042 units) 5 mm internal hex
wrench.

NOTE: Certain early production units use a single

piece retainer plate and seal carrier.

CD01D129 8
14. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm (0.2 in). If the seal carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly
tap the end of the shaft with a soft mallet.
15. Remove the O-ring from the seal carrier.
16. Place the seal carrier and seal in an arbor press
and press out old seal.

CD01D130 9

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 5

17. After removal of these components, place the

pump on a work surface with the shaft up.
18. Remove the shaft and bearing assembly from the
housing. The bearing outside diameter is a slip fit in
the housing bore.

NOTE: If the shaft and bearing stick in the housing,

lightly tap the end of the shaft with a soft mallet to free
the bearing.
19. Remove the retaining ring and press the shaft out
of the bearing.

NOTE: If the pump is equipped with an auxiliary mount- CD01D054 10

ing pad, temporarily reinstall two of the large screws
which fasten the end cover to the housing. These
screws will hold the end cover against internal spring
pressure while the small screws are removed.
20. Using a 5 mm or 6 mm internal hex wrench or a 10
mm hex wrench, remove the two or three small
screws which fasten the end cover to the pump
housing.
21. Using an 8 mm internal hex wrench for 90R042PV
pumps, a 19 mm hex wrench for 90R055PV
pumps or a 24 mm hex wrench for 90R075PV
pumps, remove the large screws which fasten the
end cap to pump housing.
22. Remove the end cover from the housing. The
alignment pins and valve plate will normally remain
with the housing. Remove the end cover gasket.
Remove the swashplate leveler spring shims (if CD01D055 11
installed) from the spring housings in the end
cover.
23. Remove the three springs from the pump: the two
long swashplate leveler (“T-Bar”) springs and the
short swashplate hold down spring.

NOTE: Certain units are equipped with dual swash-

plate leveler springs (an inner spring “nested” inside
each of the standard springs).
24. Remove the alignment pins and distribution plate,
noting the direction of the arrows on the distribution
plate.

CD01D057 12

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6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

25. Straighten the locking tabs (used on early produc-

tion units) and remove the six side cover screws
(with flat washers on later production units) using a
10 mm hex wrench for 90R042PV pumps or a
13 mm hex wrench for 90R055PV and 90R075PV
pumps.
26. Remove the side cover and the swashplate leveler
(“T-Bar”) assembly from housing.

CD01D058 13
27. Remove spring seats from swashplate leveler.
NOTE: Early production pumps do not have removable
(hardened) spring seats.
28. For units with leveler guide posts, remove the two
guide posts and sealing nuts holding the leveler to
the side cover. Use a 17 mm open end wrench or a
10 mm hex wrench on 90R042PV frame size
pumps. Use a 3/4 in open end wrench and a 13
mm hex wrench on 90R055PV and 90R075PV
frame size pumps. Remove the swash plate leveler
from the side cover. Remove the side cover O-ring.

CD01D060 14
29. Mark the servo-cylinders and housing to realign
each servo-cylinder with its respective side of the
housing.

CD01D061 15
30. Remove the three or four screws retaining each
servo-cylinder to the housing, using a 10 mm or
13 mm hex wrench.
31. For early production units, carefully pry each cylin-
der from the housing by using a screwdriver in the
notches in the cylinder. For later production units,
install a 8 mm or 10 mm screw in the threaded hole
in the center of each cylinder, and pull the cylinders
from the housing. The servo-piston will remain in
the housing.
NOTE: For later production units with displacement lim-
iters, remove the limiter screw from each servo-cylinder
and install a 8 mm or 10 mm screw in its place to act as CD01D063 16
a puller screw.

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 7

32. Remove the cylinder block through the housing

end cover opening. The swashplate and piston
assembly will remain in the housing.

CD01D064 17
33. Remove the swashplate bearing cage link pin from
the housing through the control opening.

NOTE: A flat head screw is used as the link pin in

90R042PV frame size pumps. If may be removed with
a 3 mm internal hex wrench.
34. Remove the bearing cage locator link from the
swashplate through the control opening.
35. Remove the swashplate and pistons through the
housing side cover opening. Disengage the servo-
arm from the slider block located in the servo-pis-
ton as the assembly is removed.
CD01D065 18
36. Remove the servo-piston and slider block from
housing.

NOTE: Units equipped with an automotive control have

a threaded hole in one end of the servo-piston for the
centering assistance spring assembly. For these units,
note the orientation of the servo-piston in the housing.

CD01D066 19
37. Remove the swashplate cradle bearing cage.
Remove the bearing races. The bearing races are
a loose fit on two locating pins in the housing.

CD01D067 20

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8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

38. Remove the feedback link from the head of the

special screw on the swashplate assembly.

CD01D068 21
39. Using a 10 mm or 13 mm hex wrench, remove the
four screws holding the slipper guide hold down
mechanism to the swashplate.
40. Remove the piston assemblies from the slipper
guide.

CD01D069 22

RECONDITIONING AND REPLACEMENT OF PARTS

1. After disassembly all parts should be thoroughly
cleaned in a suitable solvent. Replace all O-rings,
gaskets and the shaft seal.
2. Inspect all parts for damage, nicks, or unusual
wear patterns. Replace all parts having unusual or
excessive wear or discoloration.
3. If the end cover journal bearing needs replacement
(as shown by large amounts of the metal backing
of the bearing being visible through the plastic
bearing material), remove the bearing with a suita-
ble puller. Do not damage the valve plate surface
of the end cover.

CD01D070 23

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 9

4. Lightly lubricate the steel backing of a new journal

bearing. Press the journal bearing into the end
cover using a suitable driver.

CD01D071 24
5. When installed correctly, the bearing will be flush to
0.5 mm (0.019 in) below the distribution plate sur-
face of the end cover.

NOTE: For 90R042PV frame size pumps, the bearing

is located 21 to 21.5 mm (0.82 to 0.84 in) from the front
surface of the supply pump recess in the end cover.

CD01D072 25
6. If a new journal bearing is installed, the bearing
must be sized with the appropriate arbor to assure
the minimum bore diameter is met. Carefully press
the sizing arbor into the bearing to size it.

! WARNING !
The arbors are precision finished to size the journal
bearings without damaging them. Damaged arbors
must be replaced. Do not attempt to use the drive
shaft in place of an arbor. Inadequate clearance
between the shaft and bearing will result in inade-
quate lubrication and shortened bearing life.
CD01D073 26
NOTE: The charge pump shaft bushing in the end
cover may be replaced in a similar manner to the drive
shaft journal bearing.

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10 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

7. Certain frame size pumps with twin port end covers

may have the servo-relief valves and rotation plugs
located in a removable rotation block. Remove the
rotation block screws with a 5 mm internal hex
wrench and remove the block and gasket.
For pumps with a pressure limiter function, remove
the servo-relief valves from the end covers or rota-
tion block with a screw driver.
For pumps with the pressure limiter eliminated,
remove the servo-relief passage plug(s) from the
end cover or rotation block with a 3/16 in. internal
hex wrench.
90R042PV pump twin port end cover
CS01D533 27
Note the position of the rotation pipe plugs and
remove them from the end cover or rotation block
with a 1/8 in. internal hex wrench.
8. Install the servo-relief valves or relief valve pas-
sage plugs into the end cap or rotation block as
shown in the accompanying illustrations and chart.

NOTE: Pumps with a pressure limiter function MUST

have servo-relief valves installed in the end cover or
rotation block to limit servo-pressures.

90R055PV pump side port end cover

CS01D534 28
9. Install the rotation pipe plugs into the end cover or
rotation block as shown in the accompanying illus-
trations and chart.

90R055PV pump twin port end cover

CS01D535 29

90R075PV pump side port end cover

CS01D536 30

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 11

90R075PV pump twin port end cover rotation

CS01D537 31
Pressure limiter Servo-relief valves
Pump Pipe plugs in (0-ring plugs for O-ring plugs
Open holes
Port “A” Port “B” rotation holes automotive in holes
control in hole)
YES YES R (CW) 1, 3 6, 7 None 2, 4, 5
YES YES L (CCW) 2, 4 6, 7 None 1, 3, 5
NO NO EITHER 1, 2, 5 None 6 3, 4, 7

! WARNING !
Uncontrollable movement of the vehicle/machine
and its attachments can result from installing the
pressure limiter logic plugs in the incorrect ports for
the pump rotation. Correct pressure limiter function
MUST be verified. This can be accomplished by
testing the pump before it is installed, or by defining
and performing a test in the vehicle/machine before
it is released from repair.

Torque the servo-relief valves or relief valve passage

plugs to 12 Nm (8.85 Ib.ft). Torque the rotation pipe
plugs to 5.4 Nm (4 Ib.ft).
When reinstalling the rotation block and gasket, torque
the screws to 16 Nm (11.8 Ib.ft).
10. The threaded holes in the swashplate (for the hold
down screws) must be cleaned of old locking com-
pound prior to reassembly. A 6 mm thread tap may
be used for this purpose.
11. Inspect the swashplate guide for wear. The guide
may be removed by removing the special locking
screw with a 5 mm (042 pumps) or 6 mm (055 and
075 pump) internal hex wrench.
12. Servo-arm alignment is critical to proper pump
operation. For this reason, removal of the servo-
arm from the swashplate is not recommended.

CD01D074 32

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12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

13. If the servo-arm must be removed from the swash-

plate, remove the locking screw with a 13 mm hex
wrench.
14. “Keystone” design servo-arms must be parallel
(within 0.25 mm (0.98 in) total) to the wide surface
of the slot in the swashplate when installed. “Press
fit” design servo-arms must be carefully aligned
with the slot and threaded holes in the swashplate
while installing, and must be pressed completely
into the swashplate slot.

NOTE: “Keystone” design servo-arms and swash-

plates are no longer available for servicing 90R055PV
and 90R075PV frame size pumps. A swashplate/servo-
arm kit is available to service these units. Refer to the
appropriate Service Parts Manual for more information.
15. Torque the servo-arm to swashplate locking screw
to 32 Nm (23.6 Ib.ft).
16. Assemble the swashplate guide to the swashplate
with the special locking screw. Torque the screw to
13.5 Nm (9.95 Ib.ft) for 90R042PV pump and 32
Nm (23 Ib.ft) for 90R055PV and 90R075PV
pumps.

CD01D075 33
17. If the headed roll pin and flat washer for the bear-
ing cage locator link must be installed on the
swashplate, the distance between the washer and
the side of the swashplate must be as indicated
below:

CD01D076 34

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 13

Distance “H” ±0.010 in

Pump frame size
(±0.25 mm)
90R042PV 0.140 (3.60)
Swashplate Headed pin
90R055PV 0.21 (5.33)
90R075PV 0.240 (9.45)

Flat washer

“H”

CS01D538 35

18. Inspect the servo-piston and seal rings for wear. If

worn, remove the seal rings and expander O-rings
from the piston.
19. Install new expander O-rings into the seal grooves
in the servo-piston.
20. Carefully install the piston seal rings in the piston
grooves, over the expander O-rings. Do not stretch
the seal rings any more than necessary when
installing.
21. Lubricate the seal rings and carefully slide the
servo-piston into the servo-cylinders. Allow the
assembly to settle for at least 5 minutes to allow
the seal rings to return to their original
“unstretched” size. The remove the servo-cylin-
ders.

CD01D077 36
22. Compress the cylinder block spring and remove
the spiral retaining ring, retainer, spring, and spring
seat. Reassemble in the reverse order.

CS01D539 37

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14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

ASSEMBLY
1. Clean and lightly oil all parts prior to assembly of the
pump. Be sure to torque all threaded parts to the
recommended torque specifications.

! WARNING !
Most parts have critical, high tolerance surfaces.
Caution must be exercised to prevent damage to
these surfaces during assembly. Protect exposed
surfaces, openings, and ports from damage and for-
eign material.

2. Assemble the piston assemblies into the slipper

guide.
3. Lubricate the slipper running surfaces. Center the
pistons and guide on the swashplate.

NOTE: Later production pumps use a fixed-clearance

hold down mechanism. Early production 90R055PV
and 90R075PV frame size pumps use a spring-loaded
hold down mechanism. Service parts for the spring-
loaded hold down mechanism are no longer available.
If hold down parts require replacement on these earlier
production units, the fixed-clearance hold down mecha-
nism must be installed. Refer to the appropriate Service
Parts Manual for more information.
4. Assemble one-half of the fixed-clearance hold
down mechanism as follows: CD01D078 38

- Position two spacers over the threaded holes in the

swashplate as shown.
- Position the slipper guide bearing on top of the
spacers and the slipper guide.

! WARNING !
The “split” between the slipper guide bearing plates
must be located in line with the swashplate arm.
The bearing surface of the bearing plates must be
located next to the guide.

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 15

5. Install two new screws (with locking compound)

and flat washers through the slipper guide bearing,
and spacers. Finger tighten the screws into the
swashplate.

NOTE: Inspect the flat washers for raised edges or

“burrs”. The smooth side of the flat washers must be
installed next to the slipper guide bearing.

! WARNING !
Always use new screws with proper locking com-
pound.
CD01D079 39
6. Assemble the other half of the fixed-clearance hold
down mechanism in a similar manner.
7. Assemble one-half of the spring-loaded hold down
mechanism as follow:
8. Lubricate the slipper guide bearing and position it
on top of the slipper guide.

! WARNING !
The “Split” between the slipper guide bearing plates
must be located in line with the swashplate arm.
The bearing surface of the bearing plates must be
located next to the slipper guide.

9. Position two spacers in the holes of the guide bear-

ing and over the threaded holes in the swashplate CD01D080 40
as shown.
10. Position two flat washers on top of the spacers.
11. Position two leaf springs on top of the washers.
12. Position two spring aligners on top of the leaf
springs.
13. Install two new screws (with locking compound)
through the spring aligners, leaf springs, flat wash-
ers, and spacers. Finger tighten the screws into
the swashplate.

! WARNING !
Always use new screws with proper locking com-
pound.

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16 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

14. Assemble the other half of the spring-loaded hold

down mechanism in a similar manner. Torque the
hold down screws to 13.5 Nm (9.95 Ib.ft). The slip-
per guide and piston slippers must be able to slide
freely on the swashplate.

CD01D081 41
15. Lubricate the pistons and cylinder block bores.
Install the assembled swashplate and pistons into
the cylinder block by inserting the pistons into the
cylinder block bores. The pistons and bores are not
selectively matched, therefore no specific piston
and bore matching is required.

CD01D082 42
16. Check that the swashplate bearing race locating
pins are secure in the housing.
17. Install the swashplate bearing races into the hous-
ing, positioning the races on the locating pins.
Retain the races in position with petroleum jelly.
The locating pins are offset in the housing to
assure proper assembly.

CD01D067 43
18. Assemble and lubricate the bearing cage, and
install it on the bearing races.
19. Install the bronze slider block on the swashplate
servo-arm.

CD01D163 44

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 17

20. Install the feedback link on the head of the special

screw on the swashplate assembly.

! WARNING !
To avoid the possibility of the pump sticking in
stroke, the feedback link must NOT be installed in
pumps equipped with non-feedback controls (cover
plate, three position solenoid, and automotive con-
trol type pumps).

CD01D083 45
21. Position the servo-piston in the housing.
22. Carefully lower the cylinder block and swashplate
assembly into the housing through the end cap
opening.

NOTE: A tool to assist in holding and installing the

assembled cylinder block and swashplate may be
made from a positive lock, quick release pin and a large
flat washer (1 inch inside diameter with clearance flats
ground on the outside diameter). Insert the pin through
the cylinder block and swashplate, and lock in place
with the flat washer under the swashplate.

CD01D084 46
23. Hold the cylinder block and swashplate assembly
approximately 12 mm ( 0.47 in) above the cradle
bearings.
24. Properly position the feedback link in the control
opening.

CD01D085 47
25. Position the servo-piston on the slider block, taking
care not to wedge the block. The parts should slide
freely.

CD01D086 48

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18 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

26. Lower the cylinder block and swashplate assembly

until the swashplate is properly located on the cra-
dle bearings.

NOTE: If an assembly tool was used to install the cylin-

der block and swashplate, release and remove the pin.
The flat washer should fall through the shaft opening of
the housing.

CD01D087 49
27. Hold the servo-piston in position and install the
servo-cylinders.

NOTE: Be sure to assemble the correct servo-cylinder

on each side of the housing. For units equipped with an
automotive control, a special servo-cylinder is installed
on the centering assist spring side of the housing.
28. Install the three or four screws in each servo-cylin-
der. Torque to 13.5 Nm (9.95 Ib.ft) for 90R042PV
and 90R055PV pumps or 24 Nm (17.7 Ib.ft) for
90R075PV pumps.
29. Align the slot in the swashplate bearing cage with
the headed spring pin in the swashplate and the CD01D088 50
pin hole in the housing. Hook the cage locator link
over the spring pin, between the washer and the
swashplate. Rotate the link into the slot in the bear-
ing cage.
30. Align the hole in the locator link with the hole in the
housing and install the link anchor pin through the
link and into the housing.

CD01D089 51

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 19

For 90R042PV pump

A flat head screw is used as the link pin in 90R042PV
frame size pumps. Install a new screw (with locking Cage locator
compound) through the locator link and into the hous- Pump housing Link
ing. Tighten the screw into the housing until the head of
the screw is positioned at a height (distance “H”) of 4.53
to 4.79 mm (0.18 to 0.19 in), from the machined surface
of the pump housing. Screw

! WARNING ! “H”
Always use a new screw with proper locking com-
pound. Do NOT torque this screw against the loca-
tor link. The link MUST rotate freely.
CS01D540 52
31. Push the swashplate assembly toward the control
side of the housing until the swashplate guide con-
tacts the bearing race. Check for clearance
between the servo-arm and the slider block. If no
clearance is present, recheck the assembly of the
bearing cage and races.

CD01D090 53
32. Position the swashplate leveler (“T-bar”) on the
side cover. Note the orientation of the leveler and
the cover.

CD01D060 54

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20 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

33. For units with leveler guide posts, install the two
guide posts and sealing nuts. Torque to 9 Nm (6.63
Ib.ft) for 90R042PV pumps or 23 Nm (17 Ib.ft) for
90R055PV and 90R075PV pumps.

NOTE: If the screw holes in the side cover are

“through” holes, the threads of the screws must be
coated with sealing compound.

CD01D091 55
34. Install the leveler spring seats.

NOTE: Early production pumps do not have removable

(hardened) swashplate leveler spring seats.

CD01D092 56
35. Install the inner spring spacer washers (if used).
Install a new side cover O-ring.
36. Hold the swashplate leveler toward the end cover
end of the housing so the leveler clears the side of
the swashplate during side cover installation. Install
the side cover and swashplate leveler.

CD01D093 57

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 21

37. Install two side cover screws (with flat washers) fin-
ger tight into the blind holes in the housing, to hold
the cover while checking the “zero angle” position
of the swashplate.
38. If all the parts which affect the zero angle setting
are being reused, rotate the side cover to align the
marks on the cover and housing that were made
during disassembly.
39. Apply a force of 22 to 44 Nm (16.2 to 32.4 Ib.ft) to
the swashplate leveler to ensure both arms are in
contact with the swashplate. Make sure the swash-
plate is properly located on its bearings. Use a
depth micrometer to measure the distance from
the end cover face of the housing to the outer edge
of the swashplate surface. Take a second meas-
urement at a point 180° from the first point of
measurement (at the opposite edge of swashplate
surface). These measurements must not vary by
more than 0.025 mm (0.001 in).

CD01D094 58
40. Rotate the side cover (which will also rotate the lev-
eler and swashplate) until the zero angle position is
established, as determined by the depth measure-
ment.
41. After the zero angle position has been established,
tighten the two screws to hold the side cover.

CD01D095 59

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22 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

42. Install the remaining four screws with flat washers.

NOTE: The threads of the two side cover screws

installed in “through” holes in the housing must be
coated with a sealing compound to prevent leaks. New
screws have sealant pre-applied.
43. First, torque the four side cover screws installed in
“blind” holes to 13.5 Nm (9.95 Ib.ft) for 90R042PV
pumps or 32.5 Nm (24 Ib.ft) for 90R055PV and
90R075PV pumps. Then, torque the two side
cover screws installed in “through” holes to 10.4
Nm (7.67 Ib.ft) for 90R042PV pumps or 25 Nm
(18.4 Ib.ft) for 90R055PV and 90R075PV pumps.

CD01D096 60
44. Install the end cover alignment pins into the hous-
ing. Lubricate the running surface of the cylinder
block and install the distribution plate on the align-
ment pins.

NOTE: Note the direction of the arrow cut-outs in the

valve plate. The arrows must point in the direction of
pump rotation. For example, a right hand (clockwise)
rotation pump must have the arrows pointing in the
clockwise direction (when viewed from the shaft end).
(The photo on this page shows a valve plate installed
for clockwise (CW) rotation).
45. Install the two long springs (with inner springs, if
used) on the swashplate leveler spring seats. CD01D057 61
Install the short spring on the servo-arm link. Place
new end cap gasket on the housing (located by the
alignment pins). Take care not to bend or damage
the end cap gasket during installation.
46. Lubricate the end cover journal bearing. Install the
hardened shims in the end cover pockets for the
swashplate leveler springs. Retain the shims with
petroleum jelly.
47. Lower the end cover onto the housing, while posi-
tioning the three springs in their pockets in the end
cover.
When properly installed, the end cover will engage
on the alignment pins, but the springs will hold the
end cover 3 to 8 mm (0.11 to 0.31 in) away from
the housing.

CD01D098 62

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 23

48. Install the four large end cover screws.

NOTE: If the pump is equipped with an auxiliary mount-

ing pad, temporarily install two of the large screws
which fasten the end cover to the housing. These
screws will hold the end cover against internal spring
pressure while the small screws are installed.
Tighten the large end cover screws evenly to the
torque indicated in the accompanying table.

Frame size Torque Nm (Ib.ft)

90R042PV 75 (55)
90R055PV 122 (90) CD01D099 63
90R075PV 256 (189)
49. Install the two or three smaller screws holding the
end cover to the housing. Torque the 6 mm (0.23
in) screws to 13.5 Nm (9.95 Ib.ft) and the 8 mm
(0.31 in) screws to 38 Nm (28 Ib.ft).

NOTE: A lifting bracket is installed on one of the

smaller end cover screws.
50. Position the pump on its end cover.
Using caution to prevent damage to the sealing
surface, press the roller bearing onto the drive
shaft. (For units with a three piece bearing, press
the inner race onto the shaft, then install the outer
race/cage assembly and the special washer).
Install the bearing retaining ring on the shaft.
51. Install the screws and torque to 16 Nm (11.8 Ib.ft).
52. Install the shaft and bearing assembly through
front of the housing, aligning the shaft spline with
the cylinder block spline. Continue to lower the
shaft into the unit and carefully align the end of the
shaft with the end cover journal bearing. Then
lower the shaft and bearing assembly into position.
53. Rotate the shaft by hand. The rotating assembly
should turn freely. If it does not rotate freely, the
pump must be disassembled and the problem
found and corrected.

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24 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

54. Rotate the pump shaft with a torque wrench to

assure correct assembly. When properly assem-
bled, the torque required to turn the shaft (after
“break-away”) should be within the ranges shown
in the accompanying table.

Rolling torque (variable pump at 0°)

Ib.ft (Nm)
Frame size Minimum Maximum
90R042PV 2 (37) 7.5 (10.2)
90R055PV 4 (5.4) 9 (12.2)
90R075PV 5 (6.71) 10 (13.6)

! WARNING !
Always test the pump prior to putting it into service
to check for correct pressure limiting and control
functioning. Improper functioning of these systems
can result in uncontrollable movement of the vehi-
cle/attachments.

90R055PV pump
55. In preparation for installing the adapter plate, place
a new gasket on the housing. Place the adapter
plate into position and install the screws. Torque
the screws to 16 Nm (11.8 ft.lbs).

NOTE: A sealing washer must be installed under the

head of any mounting screws that are installed into
“thru” holes in the housing.
56. Install new O-rings and the orifice onto the electro-
valve assembly and install the electro-valve onto
the adapter plate. Install the screws and torque to
5.4 Nm (4 Ib.ft).
90R042PV and 90R075PV pump
57. In preparation for installing the control assembly,
place a new gasket on the housing. Inspect to
ensure that the control orifice check valve and
spring are in their proper position in the control
assembly.

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 25

58. While setting the control assembly into position,

engage the pin on the control linkage into the mat-
ing hole in the link attached to the swashplate.
59. With the control assembly in position, move control
assembly left and right to check engagement of pin
in the link. Proper engagement will be indicated by
an increasing resistance as the control assembly is
moved away from center position. Non-engage-
ment of pin will be indicated by lack of spring force.
In case of non-engagement, remove control
assembly and repeat the above procedure.
60. Align the control assembly gasket and install the
screws. Torque the screws to 16 Nm (11.8 Ib.ft). CD01D136 64

NOTE: A sealing washer must be installed under the

head of any mounting screws that are installed into
“through” holes in the housing.
61. Install new O-rings in the pilot-control-pressure
housing. Place the pilot-control-pressure against
the electric displacement control housing and
install the screws. Torque to 5.4 Nm (4 Ib.ft).

NOTE: Do not remove the black plastic cover from the

aluminium plate. This is not a serviceable item and will
void the product warranty.

CD01D139 65

90R042PV, 90R055PV and 90R075PV pumps

62. Install the cartridge in the multi-function valve cav-
ity and torque to 89 Nm (65.6 Ib.ft). Do not over
torque the multi-function valve cartridge.
63. Install the shim adjustable pressure relief valve,
torque to 68 Nm (50 Ib.ft).

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26 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

INSPECTION AND ADJUSTMENTS

INSPECTION OF THE SUPPLY PRESSURE

SAFETY VALVE
Mark the position of the valve in relation to the cylinder
body. Loosen the 27 mm lock nut and remove the
safety valve. Check the valve cone and seat. On reas-
sembling observe the correct position of the valve in
relation to the mark. Tighten the lock nut to a torque of
46-55 Nm (34-40.7 Ib.ft).

CD01D147 66
ADJUSTMENT OF THE SUPPLY PRESSURE
SAFETY VALVE
Loosen 27 mm lock nut and turn the adjustment plug.
By turning clockwise the pressure increases, counter-
clockwise decreases. Thereafter tighten the lock nut to
a torque of 46-55 Nm (34-40.7 Ib.ft).

CD01D148 67
ADJUSTMENT OF SAFETY PRESSURE
Turn the screw by the internal hexagonal socket while
holding the middle hexagonal head. Turning clockwise
the pressure increases, counter-clockwise decreases.
One turn changes pressure by 9.3 MPa (1349 psi).
Once in the set position, hold the adjustment screw
using key and tighten the lock nut to a torque of 16 Nm
(11.8 Ib.ft). Follow the same procedure for the second
multi-functional valve.

CD01D149 68

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 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 27

ADJUSTMENT OF THE BY-PASS VALVES

The by-pass valve is part of the multi-function valve.
Opening and closing of the valves is carried out with the
motors shut down. For the middle screw of the multi-
function valve use a 27 mm wrench and for the large
screw use a 1-1/4” wrench. Turn the middle screw three
turns counter-clockwise to open the by-pass valve. Do
not turn by more than 3.5 turns; a considerable amount
of oil would leak out.

CD01D150 69

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28 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

NOTES

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