D7G 92V

Disassemble Dozer Control Valve
1. Remove detent plugs (1), springs (2), seats (3) and balls (4).
NOTE: There are two of these detents, 180° opposite of each other
on housing (5).
2. Remove four bolts from housing (5) and remove housing from valve body.
3. Remove four bolts from control lever housing (6) and remove housing from
valve body.
4. Carefully remove spool valve (7) from valve body.

NOTE: Spool must be removed from body through the detent end.
5. Remove two plugs, (8) and (12) from the valve body. Remove shims (in the
plugs), pistons (9), springs (10) and valves (11) from the valve body.
NOTE: The plugs are marked with the pressure setting for the respective valve.
6. Remove four bolts from cover (13) and remove from valve body.
7. Remove spring (14) and valve (15).

NOTE: This is the relief valve for the tilt circuit.
8. Remove springs (17) and (18) and valve (16).
NOTE: This is the dump valve for the main relief valve.
9. Remove four bolts from valve body (19) and remove body from valve group.
10. Remove, inspect and clean shuttle valve (37) and resolver valve (38).
11. Remove four bolts from end cover (20) and remove cover from valve body.
NOTE: There is a small amount of tension on the spring behind the cover.
12. Remove springs (22) and (23), sleeve (21) and spool (24) from valve body.
NOTE: There are two more springs and a sleeve on the opposite end of spool
(24). Remove these too.
13. Remove sleeve (27), spring (26) and valve (25).
NOTE: There is another sleeve, spring and valve on the other side of the valve.
Remove these too. These are make-up valves for the tilt circuit.
14. Remove plug (31), spring (30) and valve (29) from body of valve.
NOTE: This is a make-up valve for the dozer lift. The other make-up valve is
located under plug (28). Remove it too.
15. Use a 1/4 inch hex wrench to remove bolt (36) from the end of spool (7).
Take the bolt out carefully because of force by spring (34) behind retainer (35).
Remove retainer (35) spring (34) retainer (33) and washer (32) from the
valve spool.
Assemble Dozer Control Valve
1. Install washer (32), retainer (33), spring (34) and retainer (35) on spool (7).
Put 9S3263 Thread Lock Compound on threads of bolt (36) and install
into spool.
2. Install valve (29), spring (30) and plug (31) into valve body. Do this for two
valves. Second valve is behind plug (28).
3. Install valve (25), spring (26) and sleeve (27). Be sure and use a new O-ring
seal on the sleeve. Do this for two valves, one on each side of the body.
NOTE: Do not push the sleeve in even with the valve body.
4. Install valve spool (24) for tilt circuit. Install retainer (21) and springs (22) and
(23). Install O-ring in cover (20).
5. Use four bolts and assemble cover (20) to the valve body. This will cause the
valve in Step 3 to become flush with the valve body.
6. Install shuttle valve (39) and resolver valve (40) in body.

7. Install O-rings in body and assemble to valve body with four bolts.
8. Put SAE oil on the valves. Install tilt relief valve (15) in the valve body.
Install spring (14) in valve (15). Install dump valve (16) for the main relief valve
in the valve body. Install springs (17) and (18) in the bore in dump valve (16).
9. Install seal (38) for the pilot valve of the tilt relief valve and seal (37) for the
pilot valve of the dozer relief valve. Install O-rings.
10. Install cover (13) with four bolts.
11. Install valve (11), piston (9), spring (10), shims and plug (12) in the bore for
the tilt relief valve. The plug that is marked 2500 psi is the plug for the tilt relief
valve. The plug marked 2400 psi is for the main relief valve. Install the valve,
piston, spring, shims and plug (8) for the main relief valve.
12. Put SAE 10 oil on spool (7). Install spool (7) in the valve body.
NOTE: Spool (7) for the control valve must be installed from the detent end.
13. Install control lever housing (6) with four bolts. Be sure that the pawls on the
lever engage the spool correctly.
14. Install housing (5) over the end of spool (7). Fasten the housing to the valve
body with four bolts.
15. Install ball detents (4), seat (3), spring (2) and plug (1) in housing (5). Be
sure the O-ring seal is on plug (1) before installation.
NOTE: There are two detents in housing (5). Do the procedure above for the
other detent. The chamfer side of seat (3) goes down against ball (4)
Disassemble Pilot Valve Group
NOTICE
Before pilot valve group (1) is removed from the tractor, be sure that all
the pressure in the system has been released. Disconnect the linkage and
oil lines and remove the valve from the machine.
1. Remove three bolts (2) from valve body (1).
2. With the removal of bolts (2), the group can now be divided into pilot valve (6)
for dozer tilt control, pilot valve (5) for ripper lift control, pilot valve (4) for ripper
tip control and two end manifolds (3) and (7).
3. Remove the bolts that hold cover (8) on the end opposite the shaft end of the
valve. Remove cover (8). Carefully remove spool (9) from body (5).
NOTE: The pilot valve in the illustration is used on the ripper lift or ripper tip
control.
4. Carefully put spring (11) under compression. Remove retainers (10) from the
valve spool. Slowly release the compression on spring (11).
5. Remove two bolts holding cover (12) to body (5). Remove the cover.
NOTE: There is a seal in cover (12). Check this seal for damage. If the seal is
damaged, replace with a new one. Do not remove the seal if it is not damaged.
6. Remove plug (13) from the end of the spool. This will open a passage to the
small hole (14). Check the seal on plug (13).
7. Do Steps 2 through 5 for the other two valves.
NOTE: There is no plug (Step 6) in the end of the spool for the control valve for
dozer tilt.
Assemble Pilot Valve Group

1. If necessary, install a new shaft seal in cover (12) on the shaft end of the
valve.
2. Install a new O-ring on plug (13) and install in the end of spool (14). Be sure
that the passage in spool (14) is open.
3. Put a new O-ring seal in the housing and install cover (12) on the end of the
body.
4. Assemble the valve spool with retainers and spring.
5. Install spool (9) in the valve body. Put the spool in oil for easier installation.
6. Do Steps 1 through 5 for the other valves.
7. Assemble the valves in correct order. Install three bolts (2) through the end
manifold, the valves and the remaining manifold. Tighten bolts. Be sure not to
cut an O-ring seal between each part
Disassemble Ripper Control Valve
NOTICE
Before the ripper control valve is removed from the machine, be sure
that all of the pressure in the system has been released. Disconnect the
pilot lines and pressure lines from the main system and remove the
valve assembly.
1. Remove valve seat (1), check valve (2), spring (3) and check valve (4).
2. Remove six bolts (5) and separate the valve groups.

3. Remove two bolts from end housing (6). Remove these bolts carefully
because of spring force behind the housing. Remove
end housing (6), spring (8), and retainer (7).
4. Remove spool (9).
5. Do Steps 3 and 4 for the housing (10), spring (13), retainer (12) and spool
(11) in the other valve group.
Assemble Ripper Control Valve
1. Install spool (11) in valve body. Put SAE 10 oil on the spool before
installation.
2. Put spring (13) in housing (10). Put retainer (12) over spring (13). Put the
assembly in place over the end of spool (11). Install two bolts and tighten as
much as possible by hand. Finish tighten bolts with a wrench. Be careful not to
cut the O-ring seal between the housing and the valve body.
3. Assemble the other valve group in the same way.
4. Be sure that seals (14) are in the valve body. Put the two parts together and
install the six bolts. Tighten the bolts. Be careful not to cut the O-rings between
the valve bodies.
5. Install valve (4), spring (3) and valve (2) in the valve body. Make sure the O-
ring seal on seat (1) is correctly installed. Carefully install seat (1) in the body.
Disassemble Hydraulic Tank

1. Remove the filter from the tank.
2. Remove 44 bolts (1) and carefully separate the tank in the middle. Remove
two bolts (2) and take out the manifold and tubing.
3. Remove two nuts and take off body (3). When body (3) is separated from the
tank, valve (4), spring (5) and guide (6) can be removed.
Assemble Hydraulic Tank

1. Install the manifold in the tank.
2. Install guide (6), spring (5), valve (4) and body (3). Tighten the bolts holding
the body.
3. Carefully put the two halves of the tank in alignment. Install and tighten the
44 bolts (1).
4. Install the filter. Tighten the bolt on the filter to 43 ± 2 lb. ft. (59 ± 3 N·m)
Remove Hydraulic Tank
START BY:
a) tilt cab back*
This operation location is in the Operator's Station Disassembly And Assembly

*
section.
1. Make sure the weight of all of the implements is on the ground.
2. Slowly loosen the cap on the hydraulic tank to release any pressure in the
tank.
3. Remove cover (1) from under the hydraulic tank drain valve.
4. Remove the plug from the hydraulic tank drain valve and install a 1" NPT × 6"
long pipe nipple in the hydraulic tank drain valve. Drain the oil from the hydraulic
tank. The capacity of the hydraulic tank is 16 U.S. gal. (61 liter).
5. Put identification on the hoses as to their location on the hydraulic tank for
correct assembly at installation.
6. Disconnect five hoses (2) from the hydraulic tank.

7. Remove the four bolts that hold the flanges for hose (3) to the hydraulic tank.
Disconnect the hose from the tank and remove the flanges.
8. Remove the four bolts that hold the bulldozer control valve to the hydraulic
tank.
9. Install tooling (A) to the hydraulic tank as shown. Fasten a hoist to the
hydraulic tank and remove bolts (4) and (5) that hold the angle assembly to the
tank.
10. Remove two bolts and spacers (7) that hold the hydraulic tank to the fender.
Remove hydraulic tank (6). The weight of the hydraulic tank is 248 lb. (112 kg).
Install Hydraulic Tank

1. Fasten tooling (A) to hydraulic tank (1). Fasten a hoist and put hydraulic tank
(1) in position on the fender. Install the two bolts and spacers that hold the
hydraulic tank to the fender. Tighten the bolts to a torque of 180 ± 20 lb.ft. (245
± 27 N·m).
2. Install bolts (2) and (3) that hold the two angle assemblies to the hydraulic
tank.
3. Connect the bulldozer control valve to the hydraulic tank.
4. Put hose (5) in position against the hydraulic tank and install the flanges and
bolts that hold it.
5. Connect five hoses (4) to the hydraulic tank in their original position.
6. Install the plug in the hydraulic tank drain valve and tighten to a torque of 50
± 5 lb.ft. (70 ± 7 N·m).
7. Install the cover under the drain valve.
8. Fill the hydraulic system to the correct level.
END BY:
a) tilt cab forward*
This operation location is in Operator's Station Disassembly And Assembly

*
section.
Disassemble Hydraulic Tank
START BY:
a) remove hydraulic tank
1. Remove cap (1) from the hydraulic tank.

2. Remove gasket (2), plate (4) and ball (3) from cap (1).
3. Remove ring (5) and strainer assembly (6) from the filler tube.
4. Loosen bolt (7) and remove filter assembly (8) from the hydraulic tank.
5. Remove the two nuts that hold spacer (9) to the hydraulic tank. Remove the
spacer.
6. Remove seal (10) from filter assembly (9).
7. Remove nut (12) that holds screen assembly (11) to filter element (13).
Remove the screen assembly.
8. Use a press to put the spring under compression in the screen assembly as
shown.
9. Use tool (A) to remove ring (14) from tube (15).
10. Remove spacer (16), spring (17) and valve (18) from the top of screen
assembly (11).
11. Remove tube (15) from the screen assembly.
12. Remove filter element (13) from cover (19).
13. Remove cover (19) from bolt (7).
14. Remove seal (21) and spacer (20) from bolt (7).
15. Remove manifold (22) and cover (23) from the back of the hydraulic tank.
16. Remove the bolts that hold cover (24) to tank (25). Remove the cover from
the tank. The weight of the cover is 65 lb. (29 kg).
17. Remove the two bolts and two nuts that hold flanges (28) to the base.
18. Remove two clamps (26) from the joint assembly. Remove pipe (27) and
tube (29) from the tank.
19. Remove collar (30) and seal (32) from tube (29). Remove seal (31) from the
tube.
20. Remove collar (33) and seal (34) from the tube assembly.
21. Remove the two bolts that hold base, block and plates (35) to the tank.
Remove the base, block and plates as a unit.
22. Remove seal (39) from block (37).

23. Remove the two bolts and nuts that hold plate (36) and block (37) to plate
(38). Remove plate (36) and the block from plate (38).
24. Remove seal (41) from base (40).

25. Remove the two bolts and base (40) from plate (38).
26. Remove tube assembly (42) from the tank.
27. Remove the two nuts that hold body (43) to cover (24).
28. Remove body (43) from the tank. Remove seal (46) from the body.
29. Remove guide (45) from the tank.
30. Remove valve (47) and spring (44) from the guide.
31. Remove retainer (48) from the cover.
32. Remove grommet (49) and glass (50) from retainer (48).
Assemble Hydraulic Tank
1. Install glass (1) and grommet (2) in retainer (3).

2. Install retainer (3) in cover (4) and install the four nuts that hold it.
3. Install seal (8), valve (5), spring (7) and retainer (9) in body (6).
4. Put body (6) in position on cover (4) and install the two nuts that hold it.
5. Put base (11) in position on plate (12). Install the two bolts through the plate
and the base.
6. Install seal (10) in the base.
7. Put plate (13) in position on block (14) and install the two bolts through the
plate and block. Install the plate and block on base (11) and plate (12) as
shown.
8. Install seal (15) in block (14).
9. Put tube assembly (16) in position on tank (18). All of the bolt holes must be
in alignment before the bolt is tightened.
10. Put plate and block assembly (17) in position on tank (18) and install the two
bolts that hold it.
11. Install seal (21) in tube (19).

12. Put collar (20) and seal (22) in position on tube (19).
13. Put collar (23) and seal (24) in position on the tube assembly.
14. Put pipe (25) on tube (19) and install tube (19) in the tank.
15. Install clamps (26) in on the joint assembly and tighten to a torque of 9 ± 1
lb.ft. (12 ± 1 N·m).
16. Install the two flanges that hold pipe (19) to the plate and block assembly
and install bolts (27).
17. Put gasket (28) in position on tank (18). Use two men and put cover (4) in
position on the tank. Install the bolts that hold the cover to the tank.
18. Install the O-ring seal in cover (31) and install the cover on the tank.
19. Put O-ring seal (29) in position in manifold (30) and install the manifold on
the tank.
20. Install tube (33), valve (36), spring (35) and spacer (34) in screen assembly
(32).
21. Use a press to put spring under compression in the screen assembly. Use
tool (A) to install ring (37) on tube (33).
22. Install spacer (38) and seal (39) on bolt (40).
23. Install cover (41) on bolt (40).

24. Put filter element (42) in position on cover (41).
25. Put screen assembly (32) in position over filter element (42).
26. Install the nut that holds screen assembly and filter element to
the cover. Hand tighten the nut all the way to the end of the threads (bottom
out).
27. Put seal (43) in position on cover (41).
28. Put seal (44) in position in spacer (45). Install the spacer on the tank and
install the two nuts that hold it.
29. Put filter assembly (46) in position in the tank. Tighten bolt (40) to a torque
of 43 ± 2 lb.ft. (60 ± 4 N·m).
30. Put strainer assembly (48) in position in the filler tube and install ring (47).
31. Install ball (51), plate (50) and gasket (49) in cap (52).
32. Install cap (52) on the filler tube.

END BY:
a) install hydraulic tank
Remove Pressure Control Valve
START BY:
a) tilt cab back*
This Operation Is In Operator's Station Disassembly And Assembly Section.

*
1. Disconnect four hoses (1) from the pressure control valve.
2. Remove two bolts (2) and pressure control valve (3).
Install Pressure Control Valve
1. Put pressure control valve (1) in position and install the two bolts that hold it.
2. Connect four hoses (2) to the pressure control valve.
END BY:
a) tilt cab forward*
This Operation Is In Operator's Station Disassembly And Assembly Section.

*
Disassemble Pressure Control Valve

START BY:
a) remove pressure control valve
Cover (2) holds springs (5) and (7) under compression. Remove bolts
slowly and evenly to prevent possible personal injury.
1. Remove four bolts (1), the washer and cover (2) from valve body (3).
Remove the O-rings seals from the cover.
2. Remove springs (5), spring (7), valve spool (4) and valve spool (6) from the
valve body.
3. Remove plug (11), O-ring seal (10), spring (9) and ball (8) from the valve
body.
4. If it is necessary to remove seat (12), remove plug (13) and push the seat out
with a hammer and a punch.
Assemble Pressure Control Valve
1. If the seat was removed, lower the temperature of seat (1) and install it in
valve body (2).
2. Install plug (3) in the valve body.
3. Install ball (4), spring (5), O-ring seal (6) and plug (7). Tighten plug (7) to a
torque of 25 ± 2 lb.ft. (35 ± 3 N·m).
4. Install valve spools (8) and (11) in the valve body. Put springs (9), (10) and
(12) in position in the spools.
5. Install O-ring seals (13) in cover (14).

6. Put cover (14) in position on the valve body and install the bolts and washer
that hold it.
END BY:
a) install pressure control valve
(1) 2J6089 Spring for tilt relief valve:

Length under test force ... 1.43 in.(36.3 mm)
Test force ... 67.6 ± 3.4 lb.(300 ± 15 N)
Free length after test ... 1.74 in.(44.2 mm)
Outside diameter ... .49 in.(12.4 mm)
(2) 5J4664 Spring for dump valve:
Test force ... 8.6 ± .9 lb.(38.3 ± 4 N)
(3) 2N7029 Spring for the load check valve:
Test force ... 4.00 lb.(18 N)
(4) 9J5753 Spring for the valve spool (inner):
Test force ... 7.0 ± 1.6 lb.(31.0 ± 7.1 N)
9J5754 Spring for the valve spool (outer):
Test force ... 15.0 ± 1.2 lb.(67.0 ± 5.3 N)
(5) 1L4418 Spring for the load check valve:
Test force ... 4.9 to 5.5 lb.(21.8 to 24.4 N)
(6) 3G3475 Spring for the make-up valve:
Test force ... .88 ± .04 lb.(3.9 ± .18 N)
(17) 9J5756 Spring for the shuttle valve:
Test force ... 7.0 ± 0.6 lb.(31.0 ± 2.7 N)
(8) Torque for plug when installing relief valve ... 80 ± 3 lb. ft.(110 ± 4 N·m)
(9) Thickness of 3J7470 Shim ... .048 in.(1.2 mm)
Thickness of 3J7473 Shim ... .005 in.(0.13 mm)
One 3J7473 Shim will change pressure ... 35 psi(240 kPa)
(10) 2N7029 Spring for the load check valve:
Test force ... 4.00 lb.(18.0 N)
(11) 9J5753 Spring for the valve spool (inner):
Test force ... 7.0 ± 1.6 lb.(31.0 ± 7.1 N)
9J5754 Spring for the valve spool (outer):
Test force ... 15.0 ± 1.2 lb.(67.0 ± 5.3 N)
(12) 9J5498 Spring for dump valve (outer):

Test force ... 45 ± 2.25 lb.(200 ± 10.0 N)
9J5499 Spring for dump valve (inner):
Test force ... 20 ± 1.0 lb.(90 ± 4.0 N)
(13) 2J6089 Spring for main relief valve:
Test force ... 67.6 ± 3.4 lb.(300 ± 15.0 N)
(14) 3G3475 Spring for the make-up valve:
Test force ... .88 ± .04 lb.(3.9 ± .18 N)
(15) 5J1389 Spring for the detents:
Length under test force ... .640 in.(16.26 mm)
Test force ... 9.00 ± .72 lb.(40.0 ± 3.2 N)
Free length after test ... .82 in.(20.8 mm)
(16) 3G9183 Spring for the valve spool:
Test force ... 11.1 ± .899 lb.(49.4 ± 4.0 N)
Remove Brake Hydraulic Mechanism And
Steering clutch/">Clutch Hydraulic Control Relief
Valve
START BY:
a) remove fuel tank
1. Disconnect oil lines (5) and (6) from the relief valve.
2. Disconnect oil lines (3) and (4) from the relief valve.
3. Remove bolts (2) and relief valve from the machine.
4. Remove the O-ring seals from the steering clutch hydraulic control valve.
Install Brake Hydraulic Mechanism And

Valve
1. Inspect the O-ring seals for damage and make replacements if needed.
2. Put clean oil on the O-ring seal and put O-ring seals (3) and relief valve (1) in
position on the steering clutch hydraulic control valve. Install the bolts that hold
the relief valve in place.
3. Connect oil lines (5) and (6) to the relief valve.
4. Connect oil lines (2) and (4) to the relief valve.
END BY:
a) install fuel tank
Disassemble Brake Hydraulic Mechanism And

Valve
1. Remove retaining ring (1) and plug (2) from the relief valve housing. Remove
the O-ring seal from plug (2).
Cover (3) holds spring (5) under compression.

2. Remove cover (3), O-ring seal (6), shims (7), spring (5) and valve spool (4)
from the relief valve housing.
3. Remove slug (8) from valve spool (4).
Retaining ring (12) holds spring (10) under compression.
4. Use tool (A) and remove retaining ring (12) from valve spool (4).
5. Remove retainer (11), spring (10) and plunger (9) from valve spool (4).
Assemble Brake Hydraulic Mechanism And

Valve
1. Make sure all the parts of the relief valve are clean. Put clean oil on all the
parts. Inspect all the parts for damage and make replacements if needed.
2. Install plunger (4), spring (3) and retainer (2) in valve spool (5).
3. Use tool (A) and install retaining ring (1) in valve spool (5).
4. Install slug (6) in valve spool (5).
5. Install valve spool (5), spring (7), shims (8), O-ring seal (9) and cap (10) in
the relief valve housing.
6. Install O-ring seal (11) on plug (12). Install plug (12) and retaining ring (13) in
the relief valve housing.
Remove Steering clutch/">Clutch Hydraulic Control
Valve
START BY:
a) remove brake hydraulic mechanism and steering clutch hydraulic control
relief valve.
1. Disconnect steering clutch rods (2) from the steering clutch hydraulic control
valve.
2. Remove flanges (1) and (3).
3. Remove bolts (4) that hold the steering clutch hydraulic control valve to the
bevel gear case. Remove steering clutch hydraulic control valve (5).
Install Steering clutch/">Clutch Hydraulic Control

Valve
1. Inspect all parts for damage and make replacements if needed. Put clean oil
on the O-ring seals.
2. Put O-ring seals (2) in position on the bevel gear case. Install
steering clutch hydraulic control valve (1) on the bevel gear case.
3. Connect steering clutch rods (3) to the steering clutch hydraulic control valve.
4. Make sure the O-ring seals are in place and install flanges (4) and (5).
END BY:
a) install brake hydraulic mechanism and steering clutch hydraulic control relief
valve.

Valve
START BY:
a) remove fuel tank
valve.
2. Disconnect oil line (3).
3. Disconnect oil lines (4), (5), (6), and (7) from the brake hydraulic
mechanism housing.
4. Remove four bolts (2) that hold the flanges to the bevel gear case.
bevel gear case. Remove steering clutch hydraulic control valve (9). Remove
the O-ring seals from the bevel gear case.

Valve
2. Put O-ring seals (4) in position on the bevel gear case. Install
steering clutch hydraulic control valve (1) on the bevel gear case.
3. Install the four bolts that hold the flanges to the bevel gear case.
4. Connect oil lines (5), (6), (7) and (2) to the brake hydraulic
mechanism housing.
5. Connect oil line (3) to the steering clutch hydraulic control valve.
6. Connect steering clutch rods (8) and (9) to the levers on the
steering clutch hydraulic control valve.
END BY:

Valve
START BY:
a) remove fuel tank
valve.
2. Disconnect oil line (4).
3. Remove bolts (2) and (7) that hold the clamps for oil lines (3) and (6) in place.
Remove oil lines (3) and (6).
4. Disconnect oil line (5) from the tee fitting.
5. Remove bolts (9) and (11) that hold the flanges to the bevel gear case.
bevel gear case. Remove steering clutch hydraulic control valve (10).
7. Remove O-ring seals (12) and (13) from the bevel gear case.

Valve
2. Put O-ring seals (1) and (2) in position on the bevel gear case.
3. Install steering clutch hydraulic control valve (3) on the bevel gear case.
4. Connect oil line (7) to the tee fitting.

5. Install oil lines (6) and (8). Put clamps (4) and (9) in position and install bolts
(5) and (10) that hold the clamps and flanges to the bevel gear case.
6. Connect oil line (11).

7. Connect steering clutch rods (12) to the steering clutch hydraulic control
valve.
END BY:
Disassemble Steering clutch/">Clutch Hydraulic

Control Valve
START BY:
a) remove steering clutch hydraulic control valve
Later Power Shift Shown
1. Remove flanges (3).

2. Remove the five bolts and make a separation of valve spool housing (2) from
lever housing (1).
NOTE: The following pictures of a direct drive steering clutch hydraulic control
valve.
3. Remove rings (5) and plugs (4) from the valve spool housing. Remove the O-
ring seals from the plugs.
4. Remove plungers (6).
NOTICE
Bolt (7) and washer hold springs under compression.
5. Remove bolt (7) and washer from the valve spool housing.
6. Remove bushings (8), springs (9), washers (10), valve spools (11) and
springs (12) from valve spool housing (2).
7. Remove slugs (13) and pistons (14) from valve spools (11).
8. Remove rings (17), washers (16) and springs (15) from valve spools (11).
9. Remove levers (18) from the shafts. Remove the keys from the shafts.
10. Loosen bolts (21) that hold the levers in place on the shafts.
11. Hit the ends of the shafts with a soft hammer. Remove bearings (20) and
spacers (19).
12. Remove rings (22) from shafts (23).
13. Slide the shafts out of the shaft housing and remove levers (25) and
washers (24) from the shaft housing.
14. Remove pins (27) and rollers (26) from levers (25).
15. Remove seals (28) and bearings (29) from the shaft housing.
Assemble Steering clutch/">Clutch Hydraulic Control

Valve
1. Inspect all parts for damage and make replacements if needed. Make sure all
parts of the valve are clean. Put clean hydraulic oil on all parts.
2. Use tooling (A) and install bearings (1) in the shaft housing. Make sure the
bearings are even with the seal bores.
3. Use tooling (A) and install seals (2) in the shaft housing.
4. Put rollers (6) in position in levers (3). Slide pins (5) through the levers and
rollers and install cotter pins (4).
5. Slide shafts (9) into the shaft housing. Install levers (3), rings (8) and washers
(7) on to the shafts. Make sure the grooves in the levers are in alignment with
keys (13) in the shafts. Tighten bolts (12).
6. Install spacers (10) and bearings (11) in the shaft housing.
7. Install keys (15) in the shafts. Make an alignment of the grooves in levers
(14) with keys (15) and install levers (14) on the shafts.
8. Install springs (17), washers (18) and rings (19) on valve spools (16).
9. Install pistons (21) and slugs (20) in valve spools (16).
10. Install springs (22), valve spools (16), washers (23), springs (24) and
bushing (25) in valve spool housing (26).
11. Install washer and bolt (27).

12. Install plungers (28) and (29) in valve spool housing (26).
13. Install O-ring seals (30) on plugs (32). Install plugs (32) in the valve
spool housing and install rings (31) to hold the plugs in place.
14. Put gasket (34) in place and install valve spool housing (26) on
shaft housing (33). Install the bolts that hold the housings together.
Later Power Shift Shown
15. Make sure O-ring seals (35) are in position and install flanges (36) and (37).
END BY:
a) install steering clutch hydraulic control valve
Remove Bulldozer Tilt Control Valve

1. Drain the hydraulic oil tank.
2. Remove covers (1) and (2).
3. Disconnect five lines (3) connected to the control valve.
4. Remove two bolts (4) and slide boot (5) up the control linkage rod.
5. Remove the cotter pin and pin (6) to disconnect control linkage rod (7).
6. Remove three bolts (8) and control valve (9).
Install Bulldozer Tilt Control Valve
1. Put control valve (1) in position on the machine and install the three bolts that
hold it.
2. Put control linkage rod (2) in position. Install pin (3) and the cotter pin that
holds it.
3. Slide boot (4) to position and install bolts (5) that hold it.
4. Connect five lines (6) to the control valve.
5. Put covers (7) and (8) in position and install the bolts that hold them.
Disassemble Bulldozer Tilt Control Valve
START BY:
a) remove bulldozer tilt control valve
1. Remove housing (2) from valve body (1).

2. Remove O-ring seal (3) and seal (4) from housing (2).
3. Remove two bolts (5) and housing (6) from the valve body.
4. Remove the O-ring seal from housing (6).
5. Remove valve spool (7) from the valve body.
6. Make a compression of spring (8) with tooling (A) as shown.

7. Remove retainers (9) and spring (8) from valve spool (7).
8. Remove bolts (10) and make a separation of the three sections of the valve
body.
9. Remove the O-ring seals from the sections of the valve body.
Assemble Bulldozer Tilt Control Valve
1. Install O-ring seals (1) in the sections of the valve body.

2. Put the three sections of the valve body in position and install the bolts that
hold them together.
3. Put retainers (3) and spring (4) in position on valve spool (2).
4. Make a compression of spring (4) with tooling (A) and install retainers (5) as
shown.
5. Install valve spool (2) in the valve body.
6. Put O-ring seal (6) in position in housing (7). Install housing (7) and the bolts
that hold it in position.
7. Install seal (8) in housing (10) with tooling (B).
8. Put O-ring seal (9) in position in housing (10).
9. Put oil on seal (8) and put housing (10) in position on the valve body.
END BY:
a) install bulldozer tilt control valve
Remove Bulldozer Control Valve
START BY:
a) tilt cab back *

*
section.
1. Make sure the weight of the ripper and bulldozer blade is lowered to the
ground. Make sure there is no pressure in the hydraulic system. Move the
control levers to the "FLOAT" position.
2. Slowly loosen the cap on the hydraulic tank to release the pressure in the
tank. Remove the plug from the drain valve on the bottom of the tank and install
a 1 in. NPT x 4 in. long (6B3156) Pipe Nipple to drain the hydraulic oil from the
tank. The capacity of the hydraulic tank is 16 U.S. gal. (61 liter).
3. Disconnect linkage (1) at the lever.

4. Disconnect hose (2) from the hydraulic tank.
5. Disconnect four hoses (3) from the tilt control valve.

6. Fasten a nylon strap and a hoist to frame assembly (4). Remove four bolts
(5) and remove the frame. The weight of the frame is 60 lb. (27 kg).
7. Remove the four bolts and nuts that hold angle (7) in place. Remove the
angle.
8. Disconnect all hoses (6) from the control valve.
9. Fasten a nylon strap and a hoist to the control valve. Remove two brackets
(8) that hold control valve (9) to the hydraulic tank. Remove the control valve.
The weight of the control valve is 140 lb. (64 kg).
Install Bulldozer Control Valve

1. Fasten a nylon strap and a hoist to the control valve. Put control valve (2) in
position and install brackets (1) that hold the control valve to the hydraulic tank.
2. Connect all hoses (4) to the control valve.

3. Put angle (3) in place and install the bolts and nuts that hold it.
4. Fasten a nylon strap and a hoist to the frame. Put frame assembly (5) in
position and install the bolts that hold it in place.
5. Connect four hoses (7) to tilt control valve (6).
6. Connect hose (8) to the hydraulic tank.

7. Connect linkage (9) to the lever.
8. Install the plug in the drain valve in the bottom of the hydraulic tank.
9. Fill the hydraulic system with oil to the correct level. See MAINTENANCE
GUIDE.
END BY:
a) tilt cab forward *

*
section.
Disassemble Bulldozer Control Valve
START BY:
a) remove bulldozer control valve
1. Remove lever (1) from the control valve.

2. Remove the two bolts that hold manifold (2) to the control valve. Remove the
manifold.
3. Remove two plugs (3) from cover (4).

NOTE: Plugs (3) have marks of identification with the pressure setting for the
respective valve.
4. Remove shims (6), pistons (5), springs (8) and relief pilot valves from cover
(4).
5. Remove the four bolts that hold cover (4) to the control valve. Remove
the cover.
6. Remove three O-ring seals (11) from cover (4). Remove valve seats (9) and
(10) from the cover.
7. Remove O-ring seals (12) from both of the valve seats.
8. Remove two springs (13) from the main relief valve and spring (14) from the
tilt relief valve.
9. Remove main relief valve (16) and tilt relief valve (17) from valve body (15).
10. Remove bolt (19) and four bolts (18) and remove valve body (15).
11. Remove ten O-ring seals (20) from valve body (15).
12. Remove plug (21) and the O-ring seal from the valve body.
13. Remove shuttle valve (22) and spring (23) from valve body (15).
14. Remove plug (24) and the O-ring seal from the valve body.
15. Remove resolver valve (25) from valve body (15).
16. Remove two O-ring seals (26) from resolver valve (25).
17. Remove the four bolts that hold control lever housing (27) to valve body
(28). Move the control lever housing away from the valve body and disconnect
the inner lever from the valve spool.
18. Remove the O-ring seal from the control lever housing.
19. Remove cover (29) and the gasket from control lever housing (27).
20. Remove bolt (32). Pull shaft (31) out of the control lever housing and
remove lever (30).
21. If necessary, remove the two keys from shaft (31).
22. Remove bearing (33) from control lever housing (27).

23. Remove seal (34) and bearing (35) from the control lever housing.
24. Remove detent plug (41), O-ring seal (40), spring (39), seat (38) and ball
(37) from both sides of housing (36).
25. Remove housing (36) from the valve body.
26. Remove spool valve (42) from valve body (28).
27. Put spring (43) under compression and remove retainers (44) from the
groove in bolt (45). Release the tension on spring (43) and remove
the spring and retainer (46) from bolt (45). Remove bolt (45) from the end of
valve spool (42).
There is spring tension on covers (47) and (48). Loosen the bolts that
hold the covers slowly and evenly to release the spring tension.
28. Remove covers (47) and (48) from the control valve. Remove the O-ring
seals from the covers.
29. Remove springs (50) and retainers (49) from each side of the valve body.
30. Remove tilt circuit valve spool (51) from valve body (28).
31. Remove plug (52) from each end of valve body (28).
32. Remove O-ring seal (53), valve (54) and spring (55) from plug (52).
NOTE: Valves (54) are the load check valves for the tilt circuit.
33. Remove plugs (56) from the valve body.
34. Remove valve (58), spring (57) and O-ring seal (59) from plug (56).
NOTE: Valves (58) are the makeup valves for the lift cylinders.
35. Remove plug (60) from the valve body.

36. Remove valve (62), spring (61) and O-ring seal (63) from plug (60).
NOTE: Valve (62) is the load check valve for the lift cylinder.
Assemble Bulldozer Control Valve
NOTE: Make sure all of the parts are clean and free of dirt and foreign material.
Make a replacement of damaged or worn parts with new parts. Put clean
hydraulic oil on the parts at assembly.
1. Put O-ring seal (4), spring (1) and valve (3) in position on plug (2).
2. Install plug (2) in valve body (5) as shown.

3. Install O-ring seals (9) on plugs (8). Put springs (6) and valves (7) in position
on plugs (8).
4. Install plugs (8) in valve body (5) as shown.
5. Put O-ring seals (11) in position on plugs (10). Install springs (13) and valves
(12) in plugs (10).
6. Install plugs (12) in both sides of the valve body.

8. Put plugs (16) and two springs (15) in position in each end of the valve body.
9. Put O-ring seals in position in covers (17).

10. Put covers (17) in position on valve body (5) and install the bolts that hold
them in place.
11. Put a small amount of 9S3263 Thread Lock on the threads of bolt (21).
Install bolt (21) in the end of valve spool (20). Install retainer (18)
and spring (22) over bolt (21). Put spring (22) under compression and install
retainer (19) in the groove of bolt (21). Release the tension on spring (20) until
the spring holds the retainers in position.
13. Install two O-ring seals (23) in housing (24). Put housing (24) in position on
the valve body and install the bolts that hold it.
14. Install a ball (25), seat (26), spring (27), O-ring seal (28) and plug (29) in
each side of housing (24).
15. Use tool group (A) and install bearing (30) and the seal in
lever housing (31). Make sure the lip of the seal is toward the inside as shown.
16. Use tool group (A) and install bearing (32) in hose housing (31). Make sure
the closed end of the bearing is even with the surface of lever housing (31) after
installation.
17. Install the key for lever (34) in shaft (33). Put lever (34) in position in
lever housing (31) as shown and install shaft (33). Tighten the bolt to hold lever
(34) on shaft (33).
18. Install gasket (36) and cover (35) on lever housing (31).
19. Put O-ring seals (37) in position on the lever housing.

20. Install the lever housing on valve body (5). Make sure lever (34) is engaged
correctly with valve spool (20) before the bolts are tightened.
21. Install two O-ring seals (38) on resolver valve (40).

22. Install resolver valve (40) in valve body (39) and install the O-ring seal and
plug.
23. Install spring (41) and shuttle valve (42) in valve body (39) and install the O-
ring seal and plug.
24. Install ten O-ring seals (43) in valve body (39). Put valve body (39) in
position on valve body (5) and install the bolts.
25. Install valves (44) and (45) in valve body (39).
26. Install two springs (46) and spring (47) in the valve body.
27. Install the O-ring seals on valve seats (48) and (49) and install the valve
seats in body (50).
28. Install O-ring seals (51) in body (50).

29. Put body (50) in position on valve body (39) and install the bolts that hold it
in place.
30. Install valves (55), springs (54), piston (53) and shims (52) in body (50).
31. Install the O-ring seals on plugs (56) and (57) and install the plugs in the
body and tighten to a torque of 81 ± 3 lb.ft. (110 ± 4 N·m).
NOTE: The plug with the identification 2450 psi (16900 kPa) is for the tilt relief
and the plug with the identification 2250 psi (15500 kPa) is for the main relief.
32. Install the O-ring seal in manifold (58) and put manifold (58) in position on
the valve body. Install the bolts that hold the manifold to the valve body.
33. Make sure the key is in position in the shaft and install lever (59) on the
shaft as shown. Tighten the bolt to hold the lever on the shaft.
END BY:
a) install bulldozer control valve
Remove And Install Sequence Relief Valve

1. Remove the floor plates.
2. Drain the oil from the bevel gear case and the torque divider.
3. Disconnect oil lines (1), (2), (3) and (4) from the sequence relief valve.
4. Remove the three bolts and washers that hold the sequence relief valve in
position. Remove sequence relief valve (5).
5. Install the O-ring seals on the sequence relief valve. Put clean oil on the O-
ring seals.
6. Put sequence relief valve (5) in position on the torque divider.
7. Install the three bolts and washers that hold the sequence relief valve in
position.
8. Connect oil lines (1), (2), (3) and (4) to the sequence relief valve.
9. Install the floor plates.
10. Fill the bevel gear case and the torque divider with oil to the correct level.
See MAINTENANCE GUIDE.
Disassemble And Assemble Sequence Relief Valve

START BY:
a) remove sequence relief valve
NOTE: This operation was done on an earlier sequence relief valve.
1. Remove four bolts (3) and washer. Remove two covers (1).
2. Remove three bolts (4) and washers. Remove cover (2).
3. Remove O-ring seals (5) from covers (1). Remove O-ring seals (12) from
cover (2).
4. Remove spacers (11), springs (10) and (9), stop (8), valve spool (7) and
spacer (6) from the housing.
5. Remove spacers (16), spring (15) and valve spool (14) from the housing.
6. Remove slug (13) from valve spool (14).
7. Remove ring (17) and retainer (18).

8. Remove spring (19) and plunger (20) from valve spool (14).
NOTE: The following steps are for assembly.
9. Make sure all the parts of the valve are clean. Put clean oil on the parts.
Inspect all parts for damage and make replacements if needed.
10. Put plunger (20), spring (19) and retainer (18) in valve spool (14). Install ring
(17) in valve spool (14).
11. Install O-ring seals (5) in covers (1). Install covers (1) on the housing.
12. Install spacer (6), valve spool (7) and stop (8) in the housing. Install springs
(9) and (10). Put spacers (11) in cover (2).
13. Install slug (13) in valve spool (14). Install valve spool (14) in the housing.
14. Install spring (15).
15. Put spacers (16) in cover (4). Install O-ring seals (12) in cover (4). Install the
cover on the housing.
END BY:
a) install sequence relief valve
Disassemble Pressure Control Valve
NOTICE
Before the pressure control valve is removed from the machine, be sure
that all of the pressure in the system has been released. Disconnect the
pump line and pilot lines, and remove the valve assembly.
1. Remove cover (1) from valve body. Be careful when removing

the cover, because there is spring force behind the cover.
2. Remove three springs (2), (3) and (4) from the bores in the valve body.
3. Remove valves (5) and (6).

NOTE: The larger valve will have shims in it.
4. Remove plug (7), spring (8) and ball check (9).

NOTE: There is another ball check valve in the cover. Remove it too. Keep the
parts of the two ball checks separate. They must be installed in the same bore
from which they were removed.
Assemble Pressure Control Valve
1. Install the ball check valves, springs and plugs.

NOTE: Be sure to get the ball checks back in their respective bores. These
groups are different and can not be mixed.
2. Put SAE 10 oil on valves (5) and (6). Install the valves in their repsective
bores. Install shims in the larger valve.
3. Install the spring (2) in the bore for the small valve and springs (3) and (4) in
the bore for the large valve.
4. Be sure that the seals are installed in cover (1) and install the cover with four
bolts.
NOTE: It may be necessary to use longer bolts to get compression of
the springs for assembly.
Caterpillar Products: All
Introduction
European Union Compliant, CE Marked
Important Safety Information
Illustration 1 g02139237
Think Safety
Most accidents that involve product operation, maintenance, and repair are
caused by failure to observe basic safety rules or precautions. An accident can
often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person
should also have the necessary training, skills, and tools to perform these
functions properly.
Improper operation, lubrication, maintenance, or repair of this product can
be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this
product until you have read and understood the operation, lubrication,
maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the
product. If these hazard warnings are not heeded, bodily injury or death could
occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal
Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert
"WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are
identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might
involve a potential hazard. The warnings in this publication and on the
product are therefore, not all inclusive. If a tool, procedure, work method,
or operating technique that is not recommended by Caterpillar is used,
the operator must be sure that the procedures are safe. The operator must
also be sure that the product will not be damaged or made unsafe by any
unspecified procedures.
The information, specifications, and illustrations in this publication are based on
information that was available at the time that the publication was written. The
specifications, torque, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service that
is given to the product. Obtain the complete and most current information before
you start any job.
When replacement parts are required for this product, Caterpillar
recommends using Cat replacement parts or parts with equivalent
specifications including, but not limited to physical dimensions, type,
strength, and material.
Literature Information
This manual contains safety information, operation instructions and
maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can
be different from your service tool. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of product design might have
caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication,
consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before
operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This
section provides useful information on individual parts, additional tooling, and
resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for
the experienced operator.
Photographs and illustrations guide the operator through correct procedures for
using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques
develop as the operator gains knowledge of the service tool and tool
capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and
tool disposal
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
Personal Protection/Important Information
Hazard Avoidance
Crushing Hazard (foot)
Crushing Hazard (hand)
Pinch Point
Working Load Limit (WLL) mark - Do not use

lifting device unless load identification (WLL)
markings are legible.
Safety Section
Personal injury or death can result from escaping fluid under pressure.
Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.
Always use a board or cardboard when checking for a leak.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Introduction
The 229-3612 Hydraulic Control Valve Seat Repair Kit was developed to repair
and restore worn and leaking hydraulic line relief valve seats in the hydraulic
control valve body. The kit contains four carbide cutters, four threaded inserts,
and a tool body designed to restore the valve body seat angle to factory
specifications. A case, foam insert, and operating instructions are also included
in the kit.
229-3612 Hydraulic Valve Seat Repair Kit
Table 1
Chart A
229-3612 Hydraulic Valve Seat Repair Kit
Item Part No. Description
1 ----- Tool Body
229-3615
2 Cutter, 1 1/16 inch threaded port
229-3613
3 Adapter Assembly, 1 1/16 12 inch threaded port
229-3616
229-3618
5 Adapter Assembly, 1 5/16 - 12 inch threaded port
229-3617
229-3619
7 Adapter Assembly, 1 5/8 - 12 inch threaded port
229-3620
8 Foam insert
9 6V-3072 Storage Case
6W-7301 Retaining Ring
4B-4280 Washer
361-1591
10 Adapter, M27 x 1.5 Threaded Port
361-1593
11 Cutter, M27 x 1.5 Threaded Port
Rework Procedure
To prevent hydraulic oil contamination during the rework procedure, insert a
small piece of 166-6384 Lint-Free Critical Task Wipe into the relief valve ports.
Seal all openings into the valve to prevent metal shavings from entering the
valve body and the hydraulic system. For additional protection against
contamination, the tip of the tool body contains a magnet which attracts small
metal particles to the cutter. After the procedure is completed, remove any metal
shavings from the ports, the task wipe, and flush the port with 138-
8440 Component Cleaner to prevent contamination of the hydraulic system.
Only apply light hand pressure while performing the repair operation. Excess
force and rotation will damage the seat and control valve body.
1. Clean the area around the affected line relief valve to remove any dirt or debris.
(1) Main Control Valve
(2) Typical Line Relief
2. Remove line relief valve (2) from hydraulic control valve body (1) .
Note: Check the valve seat face of the line relief valve for damage, wear, or
erosion and replace the valve, if necessary. Damage to the valve seat and valve
may also indicate contamination within the hydraulic system.
Select Adapter
3. Measure the diameter of the relief valve port and select the proper adapter and
cutter from the 229-3612Repair Kit .
(3) Tool Body
(4) Adapter
(5) Cutter
4. Assemble selected adapter (4) onto tool body (3) and tighten the adapter with a
suitable wrench.
5. Assemble selected cutter (5) on the stem of the tool body and tighten with a
suitable wrench.
Insert Task Wipes into Valve Ports
6. Insert a small piece of 166-6384 Lint-Free Critical Task Wipe into all openings in
the port of the hydraulic control valve body.
(1) Valve Body
(3) Tool Body Assembly

(4) Adapter
(5) Cutter
7. Install tool assembly (3) in the hydraulic control valve body port and hand
tighten with a suitable wrench.
(1) Valve Body
(3) Tool Body Assembly
8. Using slight downward hand-pressure, rotate the knob of tool body (3)
clockwise 2 to 3 complete rotations or until the carbide cutter has removed the
necessary material to restore the valve seat. A maximum of 0.5 mm (.020 inch) may
be removed from the seat.
9. Remove the tool body from the control valve body port.
10. Check the valve seat to ensure a complete seal.
a. Coat the seat face of the relief valve with 9U-6075 Toolmaker's Ink
or 9U-6076 Toolmaker's Ink .
a. Install the relief valve and tighten it to the specified torque.
Check for Complete Seal using Toolmakers Ink
a. Remove the valve and visually inspect the valve seat in the valve body.
 If the blue ink has transferred from the seat face of the relief
valve to the valve seat in the valve body in a continuous, non-interrupted line,
then the seal face is restored.
 If the blue ink line is not continuous, reinstall the tool and remove
additional material.
 If the blue ink does not transfer, too much material has
been removed and the valve body must be replaced.
a. If the valve body is reusable, remove the toolmaker's ink from the valve
seat and the relief valve using 9U-6077 Toolmakers Ink Remover .
Remove Foreign Object and Flush With Cleaner
11. Use 138-8440 Component Cleaner to flush the port and remove any excess
debris from the control valve body. Use a 5P-1720 Seal Pick and carefully remove any
metal shavings and the lint-free critical task wipe from the control valve port.
Note: Stamp or mark the valve to show how many times this process has been
done.
(1) Valve Body
(2) Relief Valve
12. Install relief valve (2) into control valve body (1) and tighten it to recommended
torque specifications.
13. Before operating the machine, install a high-efficiency clean-out filter. Start the
machine, and without using any implements, let the machine run for 30 minutes. For
additional information on high-efficiency clean out filters, refer to PEHP5042 Clean Out
Filters.
14. Finally, take an S O S oil sample to determine if the hydraulic system requires
further cleaning. If the system is contaminated, it can be cleaned using a Cat Kidney
Loop Filtration System.
Note: For additional information on specific applications, refer to the appropriate
service manual.
Additional Contact Information
For additional product support questions concerning this tool, contact the Cat
Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
Email: dealerservicetool_hotlinec_a_t
(1) Torque for bolt ... 43 ± 2 lb. ft.(59 ± 3 N·m)
(2) 6J468 Indicator (for filter element):
Torque for indicator ... 25 ± 2 lb. ft.(35 ± 3 N·m)
Difference between pressure of filtered and unfiltered oil when 1/2 of indicator is
seen ... 12 to 15 psi(85 to 105 kPa)
(3) 8J8443 Spring for the relief valve:
Test force ... 162 ± 16 lb.(721 ± 71 N)
Outside diameter ... 3.64 in.(92.5 mm)
(4) 7B3039 Spring for the dump valve:
Test force ... 3.50 ± .28 lb.(15.6 ± 1.2 N)
(5) Torque for plug ... 50 ± 5 lb. ft.(70 ± 7 N·m)
Disassemble Hydraulic filter/">Filter
1. Remove the filter from the tank.
2. Remove nut (1) from the bolt.
3. Remove screen assembly (5), element (3), cover (2) and bolt (4).
NOTE: This is the same procedure used to change element (2).
4. Put screen assembly (5) in a press.
5. Use tool group (A). Put ring compressor (6) in a position to set on spacer
(13). Put puller plate (7) on top of ring compressor (6). Use the press for
compression of spring (12) until spacer (13) is below snap ring (14). Use pliers
(8) to remove snap ring (14). Slowly release the force on spacer (13). Remove
spacer (13), valve (11) and tube assembly (9) from screen (10).
Assemble Hydraulic filter/">Filter
1. Install sleeve assembly (9) into screen (10). Install valve (11), spring (12) and
spacer (13) in the opposite end of screen (10).
2. Put the screen assembly in a press. Use tool group (A). Set ring compressor
(6) and puller plate (7) in place. Use the press to cause the compression
of spring (12). Install snap ring (14) with pliers (8). Be sure that snap ring (14) is
correctly installed. Slowly release the pressure on spacer (13).
3. Install element (3) and screen assembly (5) on bolt (4). Put nut (1) on bolt (4)
and tighten.
4. Install the filter in the tank.
Rotating Group Adjustments

A2FM/A2FE Motors and A2FO Pumps for "Old Style" with a Spanner Nut
Old style A2FM/A2FE motors and A2FO pumps require a spanner nut to set the
bearing preload and the rotating torques. Cup springs and a shim are used to
set the "lift off" clearance between the barrel and the port plate. New style
A2FM/A2FE motors and A2FO pumps use a snap ring for the bearing preload
and a center spring for the "lift-off" clearance.
"Old Style" A2FM/A2FE Motor and A2FO Pump
(1) Spanner nut

(2) Cup springs
Bearing Preload Adjustment for the A2FM/A2FE/A2FO "Old Style"
This section shows the proper way to set the bearing preload. If bearing preload
is too high or low, bearing life will be shortened due to heat generation.
Additionally, if bearing preload is too high the rotating torque will be too high
causing poor system operation.
Bearing group of the "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut

(3) Bolt
(4) Upper Bearing

(5) Lower Bearing
1. Install both bearings (4) and (5) onto the shaft.

2. Place the spanner nut on the shaft. Tighten the spanner nut by using a spanner
nut wrench.
3. Place a hex head bolt (3) in the shaft end.
4. Place the shaft group in the fabricated V-Block as shown in Illustration 8
5. Place 9S-7354 dial type torque wrench on the installed bolt. Hold bearing outer
races with a hand in order to prevent rotation. Turn the shaft assembly. Observe the
torque that is required to turn the shaft assembly. Compare this value with the values
from Table 4.
6. Adjust the spanner nut in order to set the required rotating torque.
7. Remove the bolt from the shaft end.
Table 4
Bearing Preload
Piston Diameter in (mm) (in) Displacement in cc Rotating torque in (Nm)(in-lb)
16
11.2 (0.441) 0.10-0.18 (0.89-1.59)
28
13.3 (0.524) 0.22-0.35 (1.95-3.10)
45
16 (0.630) 0.37-0.55 (3.27-4.87)
56
16.8 (.661) 0.45-0.70 (3.98-6.20)
63
17.8 (0.701) 0.45-0.70 (3.98-6.20)
80
18.9 (0.744) 0.75-1.10 (6.64-9.74)
90
20 (0.787) 0.75-1.10 (6.64-9.74)
107
20.6 (0.811) 1.10-1.50 (9.74-13.28)
125
22.3 (0.878) 1.10-1.50 (9.74-13.28)
131
23 (0.906) 1.10-1.50 (9.74-13.28)
160
23.6 (0.930) 1.50-1.90 (13.28-16.82)
180
25 (0.984) 1.50-1.90 (13.28-16.82)
Rotating Group Positioning for the A2FM/A2FE/A2FO "Old Style"

Bearing group of "old style" A2FM/A2FE motor and A2FO pump
(1) Spanner nut

(6) Snap ring
(7) Front cover

(8) Shim
1. Place cover (7) on shaft assembly.

Note: Measure without the adjustment shim (8)
2. Measure the distance (A) from the face of the shaft to the top of the cover.
Note: Do not include the shaft boss in measurements.
3. Measure the thickness (B) of the snap ring (6) .
4. Use dimension (C) from the Table 5 minus measured dimension (A). Then
subtract measured dimension (B) from that figure. The result is the required thickness
of the shim (8). Refer to Table 6 for the shim sizes and the associated part number.
Dimension (C) - dimension (A) - dimension (B) = required shim thickness.
Note: Multiple shim combinations may be used to achieve the desired
dimension (C) .
Table 5
Rotating Group Positioning
Displacement in cc Dimension (C) in (mm) (in)
16 76.6-76.7 (3.016-3.020)
28 76.8-76.9 (3.024-3.028)
45 83.2-83.3 (3.276-3.280)
56 89.6-89.7 (3.528-3.531)
63 89.6-89.7 (3.528-3.531)
80 99.4-99.5 (3.913-3.917)
90 99.4-99.5 (3.913-3.917)
107 111.2-111.3 (4.378-4.382)
125 111.2-111.3 (4.378-4.382)
131 111.2-111.3 (4.378-4.382)
160 120.7-120.8 (4.752-4.756)
180 120.7-120.8 (4.752-4.756)
Table 6
Adjustment Shim (8)
Displacement in cc Shim thickness in (mm)(in) Part Number
0.1 (0.004) 144-7804

16
0.3 (0.012) 144-7805
28
0.1 (0.004) 180-1376

45
0.3 (0.012) 180-1375
0.1 (0.004) 9T-2904

56
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2904

63
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2582

80
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-2582

90
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-1576

107
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576

125
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576

131
0.3 (0.012) 9T-1579
0.2 (0.008) 6E-1704

160
0.3 (0.012) 6E-1705
180 0.2 (0.008) 6E-1704

0.3 (0.012) 6E-1705
Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "Old Style"

This adjustment measures the allowable separation between the port plate and
the barrel. The "lift-off" clearance or the allowable separation can be adjusted by
adding or removing shims from the spring cup group in the center pin bore.
Excessive leakage will occur during high-pressure spikes which may lead to
rotary group damage and poor system performance if the allowable separation
is too large.
The typical lift-off clearance (F) measurement
(2) Cup spring set

(9) Port plate
(10) Housing
(11) Adjustment shim
(12) Barrel
(13) Center pin
(14) Measuring plate group

(15) Piston retaining plate
(16) Drive plates (3)
1. Insert the center pin (13). Insert the pistons. Attach the piston retaining plate
(15) to the shaft group.
2. The retaining plate (15) bolts need to be tightened to the specified torque value.
The arrangement of the 6 cup springs for A2FM/A2FE motor

The arrangement of the 4 cup springs for A2FO pumps.
Note: For ease of installation, use a punch or wire to hold spring cups in place.
3. Refer to the Illustrations 11 and 12 in order to assemble the cup springs.
4. Install the original adjustment shim (11) .
5. Fit barrel (12) over center pin (13). Insert each piston into the barrel (12) .
6. Hold the rotating group vertically in a vice by the splined shaft.
Note: Protect the splines of the shaft from damage.
7. Swivel barrel to the maximum angle.
8. Heat motor housing (10) to 80 ° C (176 ° F).
9. Fit the housing over the rotating group.
10. Allow the housing to cool.
11. Install the shims (8) that were selected from the Rotating Group Positioning
section. Install the front cover (7) and the snap ring (6) .
12. Use a press or an extractor device to tightly pull the rotary group against the
snap ring (6) .
13. Install port plate (9) in the housing.
14. Insert drive plates (16) in the center of the port plate and the barrel's center
bore.
15. Bolt the appropriate tooling (14) to the housing. Tighten until the port plate is
flush with the housing face.
Note: Tooling Selection
 for A2FM/A2FE/A2FO 28-160 cc displacement, use FT2739 Measuring
Plate Group .
 for A2FM/A2FE/A2FO 180-250 cc displacement use FT2786 Measuring
Plate Group .
16. Tighten the forcing bolt or screw until the drive plates just contact shim (11) .
17. Measure distance (D) from the face of the top of the H-Bar to the top of the
forcing bolt or screw and record.
18. Tighten the forcing bolt or screw until the cup springs (2) compress and the
center pin (13) contacts the shim (11) .
Note: Do not use excessive force once resistance is met.
19. Measure dimension (E). This is the distance from the face of the H-Bar to the
top of the forcing bolt or screw after compression.
20. Dimension (D) minus dimension (E) yields the lift-off clearance (F) .
dimension (D) - dimension (E) = dimension (F) .
21. Take the lift-off clearance (F) minus required lift-off clearance (G) from Table 7
in order to find the change in thickness of the shim.
dimension (F) - dimension (G) = change in shim thickness needed.
Note: Use only one shim for lift-off clearance adjustment.
Table 7
Lift-Off Clearance
Displacement in cc lift-off Clearance (G) in (mm) (in)
16-90 0.15-0.25 (0.006-0.010)
107-180 0.25-0.40 (0.010-0.016)
22. Select the appropriate shim from Table 8.
Table 8
Adjustment Shim (11)
1.20 (0.0470) 183-4001
1.30 (0.0512) 183-4002

16
1.40 (0.0551) 183-4003
1.50 (0.0591) 183-4000
3.50 (0.1378) 180-1279
3.60 (0.1417) 180-1278
3.70 (0.1457) 180-1277

45
3.80 (0.1496) 180-1274
3.90 (0.1535) 180-1275
4.00 (0.1575) 180-1276
7.05 (0.2776) 144-0597
7.15 (0.2815) 144-0598

56
7.25 (0.2854) 144-0599
7.35 (0.2894) 144-0600

3.60 (0.1417) 171-6861
3.70 (0.1457) 171-6860
63 3.80 (0.1496) 171-6859
3.90 (0.1535) 171-6858
4.00 (0.1575) 192-8857
3.50 (0.1378) 141-0247
3.60 (0.1417) 141-0248
3.70 (0.1457) 141-0249

80
3.80 (0.1496) 141-0250
3.90 (0.1535) 141-0251
4.00 (0.1575) 141-0252
3.50 (0.1378) 141-0247
3.60 (0.1417) 141-0248
3.70 (0.1457) 141-0249

90
3.80 (0.1496) 141-0250
3.90 (0.1535) 141-0251
4.00 (0.1575) 141-0252
3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059
107 3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
125 3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059

3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059
131 3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
3.50 (0.1378) 124-9932
3.60 (0.1417) 124-9933
3.70 (0.1457) 124-9934

160
3.80 (0.1496) 124-9935
3.90 (0.1535) 124-9936
4.00 (0.1575) 124-9937
9.95 (0.3917) 6E-1698
10.05 (0.3957) 6E-1699

180
10.15 (0.3996) 6E-1702
10.25 (0.4035) 6E-1703
23. Disassemble the motor in order to change the shim. Reassemble the motor with
the correct shim.
A2FM/A2FE Motor and A2FO Pumps - "New Style" With a Snap Ring
The new style A2FM/A2FE motors and the A2FO pumps use a snap ring and
shims to set the bearing preload. A single coil spring and the shim are used to
set the lift off clearance between the barrel and the port plate. Old style
A2FM/A2FE motors and A2FO pumps use a spanner nut to set bearing preload
and a cup spring set to adjust "lift-off" clearance.
"New Style" A2FM/A2FE motor and A2FO pump
(1) Snap ring

(2) Center spring
Bearing Preload Adjustment - A2FM/A2FE/A2FO "New Style"

Bearings for the "new style" motors and the "new style" pumps are received as
a kit. The kit includes bearings, adjustment shims, and a retaining clip. This kit
sets the necessary bearing preload.
Rotating Group Positioning - A2FM/A2FE/A2FO "New Style"
(1) Snap ring
(3) Snap ring

(4) Front cover
(5) Adjustment shim

(6) Bearing kit
1. Install bearing kit (6) and snap ring (1) on the shaft as shown.
2. Place cover (4) on shaft assembly.
Note: Make the measurements without the adjustment shim (5) installed.
3. Measure the distance (A) from the base of the shaft to the top of the cover (4) .
4. Measure the thickness (B) of the snap ring (3) .
5. Take dimension (C) from Table 9 minus measured dimension (A) minus
measured dimension (B) in order to find the required thickness for the adjustment shim.
Refer to Table 10 for the adjustment shim thickness and associated part numbers.
dimension (C) - dimension (A) - dimension (B) = required shim thickness (5) .
Table 9
Rotating Group Positioning
Displacement in cc Dimension (C) in (mm) (in)
16 76.6-76.7 (3.016-3.020)
28 76.8-76.9 (3.024-3.028)
45 83.2-83.3 (3.276-3.280)
56 89.6-89.7 (3.528-3.531)
63 89.6-89.7 (3.528-3.531)
80 99.4-99.5 (3.913-3.917)
90 99.4-99.5 (3.913-3.917)
107 111.2-111.3 (4.378-4.382)
125 111.2-111.3 (4.378-4.382)
131 111.2-111.3 (4.378-4.382)

160 120.7-120.8 (4.752-4.756)
180 120.7-120.8 (4.752-4.756)
Table 10
Adjustment Shim (5)
Displacement in cc Shim thickness in (mm) (in) Part Number
0.1 (0.004) 144-7804

16
0.3 (0.012) 144-7805
28
0.1 (0.004) 180-1376

45
0.3 (0.012) 180-1375
0.1 (0.004) 9T-2904

56
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2904

63
0.3 (0.012) 9T-2903
0.1 (0.004) 9T-2582

80
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-2582

90
0.3 (0.012) 9T-2581
0.1 (0.004) 9T-1576

107
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576

125
0.3 (0.012) 9T-1579
0.1 (0.004) 9T-1576

131
0.3 (0.012) 9T-1579
0.2 (0.008) 6E-1704
160
0.3 (0.012) 6E-1705
0.2 (0.008) 6E-1704

180
0.3 (0.012) 6E-1705
Note: Multiple shim combinations may be used to achieve the desired

dimension (C) .
Lift-Off Clearance Adjustment - A2FM/A2FE/A2FO "New Style"
This adjustment measures allowable separation between the port plate and the
barrel. The "lift off" clearance or the allowable separation can be adjusted by
adding or removing shims from the spring group in the center pin bore.
Excessive leakage will occur at high-pressure spikes if the allowable separation
is too large. The excessive leakage may lead to rotary group damage and poor
system performance.
The typical lift-off clearance (F) measurement
(2) Center spring

(7) Port plate
(8) Housing
(9) Adjustment shim
(10) Barrel
(11) Center pin
(12) Measuring plate group

(14) Drive plates (3)
1. Insert the center spring (2) and the original adjustment shim (9) into the center
bore of the barrel.
2. Insert the center pin (11) and loosely attach the piston retaining plate (13) .
3. Insert pistons and tighten retaining plate bolts.
4. Fit barrel (10) over center pin (11). Insert each piston into the barrel.
5. Hold the rotating group vertically in a vice by the splined shaft.
Note: Protect the splines of the shaft from damage.
6. Swivel barrel (10) to maximum angle.
7. Heat motor housing (8) to 80 ° C (176 ° F).
8. Fit housing (8) over the rotating group until seated.
9. Allow the housing to cool.
10. Install the shims (5) that were selected from the Rotating Group Positioning
section Table 10. Install the front cover (4) and the snap ring (3) .
11. Pull the rotary group against the snap ring (3) by using a press or an extractor
device.
12. Install port plate (7) in the housing.
13. Insert drive plates in the port plate center or the center bore of the barrel.
14. Bolt the appropriate tooling (11) to the housing. Tighten until the port plate is
flush with the housing face.
Note: Tooling Selection
 For the A2FM/A2FE/A2FO 28-160 cc displacement,
use FT2739 Measuring Plate Group .
 For A2FM/A2FE/A2FO 180-250 cc displacement use FT2786 Measuring
Plate Group .
15. Tighten the forcing bolt or screw until drive plates (14) just contact the
adjustment shim (9) .
16. Measure distance (D) from the top of the H-Bar to the top of the forcing bolt
or screw.
17. Tighten the forcing bolt until center spring (2) compresses and center pin (11)
contacts the adjustment shim (9) .
Note: Do not use excessive force once resistance is met.
18. Measure dimension (E). This is the distance from the top of the H-Bar to the top
of the forcing bolt or screw after compression.
19. Dimension (D) minus dimension (E) yields the lift-off clearance (F) .
dimension (D) - dimension (E) = dimension (F)
20. Take the lift-off clearance (F) minus the required lift-off clearance (G) from Table
11 in order to find the change of the thickness of the shim.
dimension (F) - dimension (G) = the needed change in shim thickness
Note: Use only one shim for lift-off clearance adjustment.
Table 11
Lift-Off Clearance
Displacement in cc Lift-off Clearance (G) in (mm) (in)
16-90 0.15-0.25 (0.006-0.010)
107-180 0.25-0.40 (0.010-0.016)
Table 12
Adjustment Shim (9)
1.20 (0.0470) 183-4001
1.30 (0.0512) 183-4002

16
1.40 (0.0551) 183-4003
1.50 (0.0591) 183-4000
45 3.50 (0.1378) 180-1279
3.60 (0.1417) 180-1278
3.70 (0.1457) 180-1277

3.80 (0.1496) 180-1274
3.90 (0.1535) 180-1275
4.00 (0.1575) 180-1276
7.05 (0.2776) 144-0597
7.15 (0.2815) 144-0598

56
7.25 (0.2854) 144-0599
7.35 (0.2894) 144-0600
3.60 (0.1417) 171-6861
3.70 (0.1457) 171-6860
63 3.80 (0.1496) 171-6859
3.90 (0.1535) 171-6858
4.00 (0.1575) 192-8857
3.50 (0.1378) 141-0247
3.60 (0.1417) 141-0248
3.70 (0.1457) 141-0249

80
3.80 (0.1496) 141-0250
3.90 (0.1535) 141-0251
4.00 (0.1575) 141-0252
3.50 (0.1378) 141-0247
3.60 (0.1417) 141-0248
3.70 (0.1457) 141-0249

90
3.80 (0.1496) 141-0250
3.90 (0.1535) 141-0251
4.00 (0.1575) 141-0252

3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059
107 3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059
125 3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
3.60 (0.1417) 171-3060
3.70 (0.1457) 171-3059
131 3.80 (0.1496) 171-3058
3.90 (0.1535) 171-3057
4.00 (0.1575) 171-3054
3.50 (0.1378) 124-9932
3.60 (0.1417) 124-9933
3.70 (0.1457) 124-9934

160
3.80 (0.1496) 124-9935
3.90 (0.1535) 124-9936
4.00 (0.1575) 124-9937
180 9.95 (0.3917) 6E-1698
10.05 (0.3957) 6E-1699
10.15 (0.3996) 6E-1702

10.25 (0.4035) 6E-1703
22. Disassemble to remove the shim then reassemble using the correct shim.
A4VG - Series 32
Lift-Off Clearance Adjustment - A4VG
This adjustment measures allowable separation between the port plate and the
barrel. The "lift-off" clearance or the allowable separation can be adjusted by
adding or removing shims from the center springunder the ball joint. Excessive
leakage will occur at high-pressure spikes if the allowable separation is too
large. Excessive leakage may lead to rotary group damage and poor system
performance.
Typical A4VG pump
(1) Piston retaining ring

(2) Ball joint
(3) Adjustment shims

(4) Spring group
(5) Barrel
(6) Port Plate
Required tooling

(2) Ball joint
(5) Barrel
(6) Port Plate
(7) Measuring bell
(8) Test ring or pins (3)
(9) Measuring hub

(10) Alignment plug
1. Select proper tooling from Table 13.
Table 13
Piston
Hub (9) Test ring (8) Plug (10)
diameter Displacement Bell (7) Part Test Pins
Part Part Part
in in cc number
number number number
mm (in)
15.2 40 135-8293 128-2744 135-8295 135-8291

(0.598)
17 (0.669) 56 128-2743 128-2744 128-2745 128-2741
18.4 71 135-8294 128-2744 135-8296 135-8292

(0.724)
19.9 90 128-2747 128-2744 129-3877 129-3882

(0.783)
22.2 125 129-3873 129-3876 129-3878 129-3883

(.874)
25.1 180 129-3875 129-3876 129-3879 129-3884

(0.988)
171-1112
31 (1.22) 250 171-1113 129-3876 171-1114 (1)
(1)
3 171-1112 Test Pins are needed.
2. Place the port plate (6) on the surface plate. The flat side of the port plate (6)
must be facing downward.
3. Place alignment plug (10) on the port plate (6). The chamfer side of the
alignment plug (10) must be facing upward.
4. Place barrel (5) on the port plate and the alignment plug.
5. Place test ring (8) on barrel in place of springs.
6. Install ball joint (2) over the test ring on barrel.
7. Place the piston retaining ring (1) over the ball joint.
8. Bolt tool (7) and tool (9) together. Refer to Illustration 17 in order to set the tool
(7) and the tool (9) on the barrel.
9. Measure the distance from the surface plate to the top of the measuring bell in
order to find dimension (A) .
10. Dimension (B) is scribed on the top of the measuring bell (7) .
11. Measured dimension (A) minus dimension (B) yields dimension (C) .
dimension (A) - dimension (B) = dimension (C)
Note: Do not measure the distance from the surface plate to the top of the
piston retaining plate in place of dimension (C). The piston retaining plate may
not be square with the surface plate, and the measurement will not be accurate.
12. Required lift-off clearance (D) from Table 14 minus calculated dimension (C)
equals the required shim thickness (3) .
dimension (D) - dimension (C) = required shim thickness.
Table 14
Lift-Off Clearance
Displacement in cc Dimension (D) in (mm)(in)
40 89.40-89.60 (3.5197-3.5276)
56 99.86-100.06 (3.9315-3.9394)
71 108.50-108.70 (4.2717-4.2795)
90 117.20-117.40 (4.6142-4.6220)
125 130.80-131.00 (5.1496-5.1575)
180 148.00-148.20 (5.8268-5.8346)
250 170.95-171.20 (6.7303-6.7402)

Note: Use only one shim for adjustment of lift-off clearance.
Table 15
Adjustment Shim (3)

Displacement in cc Shim thickness in (mm) (in) Part number
0.60 (0.0236) 127-4198
0.80 (0.0315) 127-4197

40
1.00 (0.0394) 127-4196
1.20 (0.0472) 127-4195
0.60 (0.0236) 117-7248
0.80 (0.0315) 117-7247

56
1.00 (0.0394) 117-7246
1.20 (0.0472) 117-7245
0.60 (0.0236) 142-9433
0.80 (0.0315) 142-9432

71
1.00 (0.0394) 142-9431
1.20 (0.0472) 142-9430
0.60 (0.0236) 126-1408
0.80 (0.0315) 126-1407

90
1.00 (0.0394) 126-1406
1.20 (0.0472) 126-1405
0.60 (0.0236) 6E-4367
0.80 (0.0315) 6E-4366

125
1.00 (0.0394) 6E-4365
1.20 (0.0472) 6E-4364
180 0.60 (0.0236) 6E-4367
0.80 (0.0315) 6E-4366
1.00 (0.0394) 6E-4365

1.20 (0.0472) 6E-4364
0.50 (0.0197) 164-8169

250
0.75 (0.0295) 164-8170
14. Remove the tooling and install the appropriate shim between the barrel and
the spring group.
A6VM/A6VE Motor
Typical A6VM motor
Bearing Preload Adjustment - A6VM/A6VE 55/140/160 cc

The bearings are received in a kit. The kit includes bearings, adjustment shim,
and the retaining clip. This kit sets the necessary bearing preload.
Bearing Preload Adjustment - A6VM/A6VE 28/80/107/200 cc
28/80/107/200 cc motor
(1) Snap ring

(2) Adjustment shim
(3) Upper bearing

(4) Adjustment shim
(5) Lower bearing
1. Install the lower bearing (5) on the shaft.

2. Measure dimension (B) and the thickness of the lower bearing.
3. Take dimension (A) from the Table 16 minus the measured dimension (B) in
order to find the required thickness of the shim (4) .
dimension (A) - dimension (B) = required shim thickness.
Table 16
Bearing Preload
Piston Diameter
Displacement in cc Dimension (A) in (mm) (in)
mm (in)
28 34.95-35.05 (1.3760-1.3800)
16 (0.6299)
80 40.95-41.05 (1.6122-1.6161)
22.8 (0.8976)
107 44.95-45.05 (1.7697-1.7736)

25 (0.9842)
160 50.95-51.05 (2.0059-2.0098)

28.7 (1.130)
200 52.95-53.05 (2.0846-2.0886)

30.8 (1.2126)
4. Use Table 17 to find an appropriate adjustment shim (4).
Table 17
Adjustment Shim (4)
Displacement in cc Shim thickness (mm) (in) Part number
28 5.90 (0.2323) 209-9972
80 3.80 (0.1496) 123-5754
3.85 (0.1516) 123-5755
3.90 (0.1535) 124-6459
3.95 (0.1555) 123-5757

4.00 (0.1575) 123-5758
5.80 (0.2283) 124-9865
5.85 (0.2303) 124-9866
107 5.90 (0.2323) 124-9867
5.95 (0.2343) 124-9868
6.00 (0.2362) 124-9869
4.80 (0.1890) 145-8429
4.85 (0.1909) 145-8430
200 4.90 (0.1929) 145-8431
4.95 (0.1949) 145-8432
5.00 (0.1969) 145-8433
5. Install the appropriate adjustment shim (4) and install upper bearing (3) on the
shaft.
Note: Make sure that upper bearing is fully pressed against lower bearing.
6. Place the snap ring (1) on the shaft.
Note: For A6VM107, 142-1380 plate must be placed on the shaft before the
retaining ring. This is a required shim.
7. Select an appropriate shim from the Table 18. The adjustment shim (4) should
make the distance between the snap ring (1) and the upper bearing (2) less than 0.05
mm (0.0020 in).
Table 18
Adjustment Shim (2)
28 2.15 (0.0846) 209-9964
2.20 (0.0866) 209-9965
2.25 (0.0886) 209-9966
2.30 (0.0906) 209-9967
2.35 (0.0925) 209-9968

2.40 (0.0945) 209-9969
2.45 (0.0965) 209-9970
2.50 (0.0984) 209-9971
2.65 (0.1043) 123-5763
2.70 (0.1063) 123-5764
2.75 (0.1083) 123-5765
2.80 (0.1102) 123-5766

80
2.85 (0.1122) 123-5767
2.90 (0.1142) 123-5768
2.95 (0.1161) 123-5789
3.00 (0.1181) 123-5770
3.15 (0.1240) 124-9877
3.20 (0.1260) 124-9876
3.25 (0.1280) 124-9875
3.30 (0.1300) 124-9874

107
3.35 (0.1319) 124-9873
3.40 (0.1339) 124-9872
3.45 (0.1358) 124-9871
3.50 (0.1378) 124-9870
200 3.15 (0.1240) 145-8434
3.20 (0.1260) 145-8435
3.25 (0.1280) 145-8436
3.30 (0.1300) 145-8439

3.35 (0.1319) 145-8440
3.40 (0.1339) 145-8441
3.45 (0.1358) 145-8442
3.50 (0.1378) 145-8443
8. Remove the snap ring from the shaft. Install the proper adjustment shim on the
shaft. Replace the snap ring on the shaft.
Bearing Preload Adjustment - A6VM/A6VE 250 cc
This section shows the proper way to set the bearing preload. The bearing life
will be shortened due to the heat generation if bearing preload is too high or
low. Additionally, if bearing preload is too high the rotating torque will be too high
250 cc Motor
(6) Snap ring
(7) Required shim
(8) Upper bearing

(9) Adjustment shim
(10) Lower bearing
1. Press lower bearing (10) on the shaft.

2. Measure dimension (D) by measuring the distance from the shaft base to top of
the lower bearing.
3. Take dimension (C) from Table 19 minus the measured dimension (D) in order
to find the required adjustment shim thickness.
dimension (C) - dimension (D) = required shim thickness.
Table 19
Bearing Preload
Piston Diameter
Displacement in cc Dimension (C) in mm (in)
mm (in)
250 86.0-87.0 (3.3858-3.4252)

32 (1.2598)
4. Use Table 20 to find an appropriate shim (9).
Table 20
Adjustment Shim (9)
Displacement in cc Shim thickness in mm (in) Part number
7.35 (0.2894) 9T-9453 - kit
7.40 (0.2913) 9T-9453 - kit
250 7.45 (0.2933) 9T-9453 - kit
7.50 (0.2953) 9T-9453 - kit
7.80 (0.3071) (1)

9T-9453 - kit
(1)
Can be ground to size if required.
5. Install appropriate shim (9) and press upper bearing (8) on shaft.
6. Install required shim (7) on shaft and install snap ring (6) .
Bearing Preload Adjustment - A6VM/A6VE 355 cc
355 cc Motor
(11) Snap ring

(12) Front cover
(13) Upper bearing

(15) Lower bearing
1. Install bearing (15) and shim (14) onto the shaft.

2. Place front cover (12) on the shaft.
3. Measure dimension (G). This is the distance from shaft base to the snap ring
area of the front cover.
4. Measure thickness (F) of snap ring (11) .
5. Take dimension (E) from Table 21 minus measured dimension (F) minus
measured dimension (G) in order to find the required change in the thickness of the
adjustment shim (14) .
dimension (E) - dimension (F) = required change in shim thickness
Table 21
Bearing Preload
Piston Diameter
Displacement in cc Dimension (E) in (mm) (in)
mm (in)
355 147.95-148.05 (5.8248-5.8287)

36 (1.4173)
6. Select appropriate adjustment shim (14) from Table 22.
Table 22
Displacement in cc Shim thickness (mm) (in) Part number
355 7.30 (0.2874) 191-0678 - kit
7.35 (0.2894) 191-0678 - kit
7.40 (0.2913) 191-0678 - kit
7.45 (0.2933) 191-0678 - kit

7.90 (0.3110) (1)
191-0678 - kit
(1)
Can be ground to size if required.
7. Remove the front cover and the upper bearing. Insert the appropriate shim and
reassemble using the upper bearing (13) .
Lift-Off Clearance Adjustment - A6VM/A6VE 28-200 cc with the Type 1 Barrel
adding or removing shims from the spring group in the center pin bore.
Excessive leakage will occur at high-pressure spikes which may lead to rotary
group damage and poor system performance if the allowable separation is too
large.
Typical lift-off clearance (H) measurement of A6VM/A6VE with type 1 barrel
(17) Housing
(19) Center pin

(20) Type 1 barrel
(21) Port plate

(22) Head group
Type 1 barrel
Lift-off clearance for a Type 1 barrel is adjusted via a shim (16). The shim (16) is
placed in the center bore of the barrel.
Required Equipment
149-4935 Pump and Motor Measuring Group
1. Insert the complete drive shaft and the bearing assembly with the center pin
(19) and the piston retaining plate (18) into the housing (17) .
2. Tightly pull the rotary group against the case cover using a press or an extractor
device.
3. Select the correct gauge plate from the Table 23 to use from kit 149-4935 Pump
and Motor Measuring Group .
Table 23
Gauge Plates in 149-4935 Pump and Motor Measuring Group
Piston Diameter
Displacement in cc Part number Gauge Plate Thickness mm (in)
mm (in)
20 55 149-4928 9.10
(0.7874) (0.3583)
22.8 80 149-4930 3.80

(0.8976) (0.1496)
25 107 149-4931 3.50

(0.9843) (0.1378)
28.7 160 149-4932 4.50

(1.1300) (0.1772)
30.8 200 149-4934 4.00

(1.2126) (0.1575)
4. Place three 149-5141 gauge balls in the top of the gauge plate.
Note: "TOP" is engraved on the gauge plate.
5. Press the balls gently in the gauge plate.
Note: Do not press the balls completely in the gauge plate. Hold the balls in
place by pressing firmly on the balls. Only apply enough pressure in order to
hold the balls in place.
Note: The lead balls vary in size. The lead balls must protrude from the gauge
plate at least 2.10 mm (0.0827 inch) prior to Step 6 in order to ensure proper
compression of the lead balls.
6. Place a small amount of grease on the top side of the gauge plate.
7. Place the "TOP" side of the gauge plate and the balls into the center pin bore of
the barrel (20). The grease should hold the gauge plate in place inside the barrel.
8. Install the cylinder barrel on the center pin.
Note: Do not drop the barrel onto the center pin. This will lead to premature
crushing of the lead balls.
9. Install the port plate (21) and the head group.
10. Tighten all of the head bolts to the specified torque while the pump shaft is
turning.
Note: The pump shaft must be rotated while tightening bolts in order to seat all
components.
11. Loosen and remove the head group and the port plate.
12. Remove barrel from center pin.
13. Carefully remove the gauge plate and the flattened balls from the barrel.
14. Measure the thickness of the gauge plate and flattened balls at each gauge ball
location. These are dimensions (X1), (X2), and (X3) .
Note: Repeat the procedure if the measurements at each of the three gauge
ball locations are not within 0.05 mm (0.002 in).
Gauge plate after removal from barrel. The lead shot compressed at each of the three ball locations.
15. Take the average value of (X1), (X2), and (X3). Call this dimension (X) .
(dimension (X1) + dimension (X2) + dimension (X3) ) / 3 = dimension (X) .
16. Take dimension (X) minus the required lift-off clearance (Z) from Table 24 in
order to find the required thickness of the shim.
dimension (X) - dimension (Z) = required shim thickness.
Table 24
Lift-Off Clearance
Displacement in cc Lift-off Clearance (Z) in (mm) (in)
28
0.150-0.300 (0.006-0.012)
55
0.150-0.250 (0.006-0.010)
80
0.150-0.250 (0.006-0.010)
107
0.150-0.250 (0.006-0.010)
140 0.200-0.400 (0.008-0.016)
160 0.200-0.300 (0.008-0.012)
200 0.100-0.300 (0.004-0.012)
17. Select the appropriate adjustment shim (16) from Table 25.
Table 25
3.50 (0.138) 180-1279
3.60 (0.1427) 180-1278
3.70 (0.146) 180-1277

28
3.80 (0.150) 180-1274
3.90 (0.154) 180-1275
4.00 (0.158) 180-1276
3.50 (0.138) 137-4586 (kit)
3.60 (0.141) 137-4586 (kit)
3.70 (0.146) 137-4586 (kit)

55
3.80 (0.150) 137-4586 (kit)
3.90 (0.154) 137-4586 (kit)
4.00 (0.158) 137-4586 (kit)
80 3.50 (0.138) 123-5773

3.60 (0.142) 123-5774
3.70 (0.146) 123-5775
3.80 (0.150) 123-5776
3.90 (0.154) 123-5777
4.00 (0.158) 123-5778
3.50 (0.138) 124-9932
3.60 (0.142) 124-9933
3.70 (0.146) 124-9934

107
3.80 (0.150) 124-9935
3.90 (0.154) 124-9936
4.00 (0.158) 124-9937
4.50 (0.177) 124-9855
4.60 (0.181) 124-9856
4.70 (0.185) 124-9857

140
4.80 (0.189) 124-9858
4.90 (0.193) 124-9859
5.00 (0.197) 124-9860
4.50 (0.177) 124-9855
4.60 (0.181) 124-9856
4.70 (0.185) 124-9857

160
4.80 (0.189) 124-9858
4.90 (0.193) 124-9859
5.00 (0.197) 124-9860
200 5.50 (0.217) 145-8452

5.60 (0.221) 145-8453
5.70 (0.224) 145-8454
5.80 (0.228) 145-8455
5.90 (0.232) 145-8456
6.00 (0.236) 145-8457
18. Reassemble the motor with the appropriate shims.

Lift-Off Clearance Adjustment - A6VM/A6VE 200/250/355 cc with the Type 2 Barrel
placing shims of different thicknesses under the screw in the Type 2 barrel. The
shim sets the depth that the screw can protrude into the center pin bore of the
barrel. Excessive leakage will occur at high-pressure spikes which may lead to
rotary group damage and poor system performance if separation is too large.
Typical lift-off clearance (J) measurement of A6VM/A6VE with type 2 barrel
(23) Center pin

(24) Center pin disk

(26) Screw

(28) Type 2 barrel
(29) Port plate
Type 2 barrel
(23) Center pin
(24) Center pin disk
(26) Screw
Lift-off clearance for Type 2 barrel is adjusted via shim (25) that sets the depth
screw (26) can protrude into the center pin bore of the barrel.
Required Equipment
1. Insert the complete drive shaft and the bearing assembly with the center pin
(23) and piston retaining plate (27) into the housing.
2. Install the front cover, the shim, and the snap ring.
Note: Only for the 355 cc displacement pumps and motors.
3. Tightly pull the rotary group against the case cover using a press or an extractor
device.
4. Tighten the barrel screw (26) with the largest shim (25) from Table 29.
5. Select the appropriate gauge group from 149-4935 Pump and Motor Measuring
Group .
Table 26
Gauge groups in 149-4935 Pump and Motor Measuring Group
Piston Diameter
Displacement in cc Part number
mm (in)
200 149-4934
30.8 (1.2125)
250 149-4934
32 (1.2598)
355 149-4934
36 (1.4173)
(30) Spring pin
(31) Disc springs

(32) Gauge disc
6. Refer to Illustration 27 in order to set the gauge disc (32) so that the gauge disc
(32) is centered on the middle of the spring pin (30).
7. Place a small amount of grease between the disc springs (31) and the gauge
disc (32). Place a small amount of grease on the side of the disc spring (31) in order to
be inserted into the barrel.
Note: Leave the center pin disc (24) out during the measurement procedure.
8. Place the gauge assembly in the center pin bore of the cylinder barrel so that
the disc springs are facing toward the barrel screw. The grease should hold the gauge
plate in place.
9. Install the cylinder barrel (28) on the center pin (23) .
Note: The resulting measurement will be incorrect if the barrel is dropped onto
the center pin.
11. Tighten all of the bolts to the specified torque while the pump shaft is turning.
Note: Tighten all of the bolts while the pump shaft is rotating in order to seat all
of the components.
12. Loosen and remove the head group and the port plate (29) .
13. Remove barrel from center pin (23) .
14. Carefully remove the gauge group from the barrel cylinder.
15. Remove the disc springs (31) from the gauge group.
16. Measure the thickness of the gauge group (K) from the top of the spring side of
the spring pin (30) to the bottom of the gauge disc (32) as in Illustration 28.
17. Use Table 27 to assist in calculating the required shim thickness.
Table 27
Explanation of Dimensions
Dimension
Description
K Measurement from Illustration 28
L Lift-off clearance
M Ideal center pin disc thickness
C Center pin disc thickness

Difference between ideal center pin disc thickness (M) and center pin disc
X
thickness (C)
S Shim thickness used during measuring procedure (1)
Z Required shim thickness for proper lift-off adjustment

(1)
This is shim (25) from Illustration 26
19. Use the formulas below to calculate the required shim thickness.
20. K-L=M
21. M-C=X
22. S-X=Z
23. Note: If (M) is less than (C), you will need to add shim thickness
compared to shim (25) used during testing. If (M) is greater than (C), you will
need to reduce shim thickness compared to shim (25) used during testing.
24. Note: Be sure the difference between the shim thickness you want (Z)
and the shim thickness you have to choose from Table 29 are within the
tolerance given in Table 28.
25. Note: Use only one shim for the adjustment of the lift-off clearance.
Table 28
Lift-Off Clearance
Displacement in cc Dimension (L) in (mm) (in)
0.25 ± 0.05 (0.0098 ± 0.0020)

200
0.20 ± 0.10 (0.0079 ± 0.0039)

250
0.25 ± 0.10 (0.0098 ± 0.0039)

355
18. Select appropriate shim (25) from Table 29.
Table 29
200 5.50 (0.2165) 145-8452

5.60 (0.2205) 145-8453
5.70 (0.2244) 145-8454
5.80 (0.2283) 145-8455
5.90 (0.2323) 145-8456
6.00 (0.2362) 145-8457
1.70 (0.0669) 9T-9450 (kit)
1.75 (0.0689) 9T-9450 (kit)
1.80 (0.0709) 9T-9450 (kit)
1.85 (0.0728) 9T-9450 (kit)
1.90 (0.0748) 9T-9450 (kit)
1.95 (0.0768) 9T-9450 (kit)
2.00 (0.0787) 9T-9450 (kit)
2.05 (0.0807) 9T-9450 (kit)

250
2.10 (0.0827) 9T-9450 (kit)
2.15 (0.0846) 9T-9450 (kit)
2.20 (0.0866) 9T-9450 (kit)
2.25 (0.0886) 9T-9450 (kit)
2.30 (0.0906) 9T-9450 (kit)
2.35 (0.0925) 9T-9450 (kit)
2.40 (0.0945) 9T-9450 (kit)
2.90 (0.1142) 9T-9450 (kit)
355 1.70 (0.0669) 191-0666 (kit)
1.75 (0.0689) 191-0666 (kit)
1.80 (0.0709) 191-0666 (kit)

1.85 (0.0728) 191-0666 (kit)
1.90 (0.0748) 191-0666 (kit)
1.95 (0.0768) 191-0666 (kit)
2.00 (0.0787) 191-0666 (kit)
2.05 (0.0807) 191-0666 (kit)
2.10 (0.0827) 191-0666 (kit)
2.15 (0.0846) 191-0666 (kit)
2.20 (0.0866) 191-0666 (kit)
2.25 (0.0886) 191-0666 (kit)
2.30 (0.0906) 191-0666 (kit)
2.35 (0.0925) 191-0666 (kit)
2.40 (0.0945) 191-0666 (kit)
2.90 (0.1142) 191-0666 (kit)
19. Disassemble the barrel. Replace the shim. Reassemble the barrel.
A8VO Pump
Typical A8VO motor rotating group
Bearing Preload Adjustment - A8VO 107/160 cc

This section shows the proper way to set the bearing preload. Bearing life will
be shortened due to heat generation if bearing preload is too high or too low.
(1) Locknut
(2) Adjustment shim

(3) Middle bearing
(4) Lower bearing
1. Place both bearings on the surface plate.

2. Measure dimension (B) by measuring the distance from the surface plate to the
top of the middle bearing.
3. Take dimension (A) from Table 30 minus measured dimension (B) in order to
find the required thickness of the shim (8) .
dimension (A) - dimension (B) = required shim thickness.
4.
Table 30
Bearing Preload
Piston Diameter
Displacement in cc Dimension (A) in (mm) (in)
mm (in)
107 75.95-76.00 (2.9902-2.9921)
25 (0.9842)
160 86.45-86.50 (3.4035-3.4055)

28.7 (1.1300)
Table 31
Adjustment Shim (2)
2.70 (0.1063) 9T-3376
2.80 (0.1102) 9T-3377
107 2.90 (0.1142) 9T-3378
3.00 (0.1181) 9T-3379
3.10 (0.1220) 9T-3380
6.2 (0.2441) 5I-4480
6.3 (0.2480) 5I-4481
160 6.4 (0.2520) 5I-4482
6.5 (0.2559) 5I-4483
6.6 (0.2598) 5I-4484
6. Press lower bearing (4) and middle bearing (3) on the shaft.
7. Install the adjustment shim (2) .
8. Press the upper bearing on the shaft.
9. Tighten the locknut (1) on the shaft.
10. Place a hex head bolt in the shaft end.
11. Refer to Illustration 31 to place the shaft group in the fabricated V-Block
12. Place a breaker bar on the installed bolt and hold the bearing's outer races with
a hand. Ensure that the shaft rotates with a slight to moderate force.
13. Remove the bolt before assembling the pump.
Bearing Preload Adjustment - A8VO 200 cc
This section shows the proper way to set the bearing preload. Bearing life will
be shortened due to heat generation if bearing preload is too high or low.
(5) Snap ring
(6) Adjustment shim

(7) Upper bearing
(8) Adjustment shim

(9) Middle bearing
(10) Lower bearing
1. Place middle bearing (9) and lower bearing (10) on the surface plate.
2. Measure dimension (F) by measuring the distance from the surface plate to the
top of the middle bearing.
3. Dimension (E) from Table 32 minus measured dimension (F) yields the required
shim thickness.
dimension (E) - dimension (F) = required shim thickness.
4.
Table 32
Bearing Preload
Piston Diameter
Displacement in cc Dimension (E) in (mm) (in)
mm (in)
200 86.4-86.5 (3.4016-3.4055)

30.8 (1.2125)
5. Select appropriate adjustment shim (8) from Table 33.
Table 33
Adjustment Shim (8)
6.20 (0.2441) 177-2513
6.30 (0.2480) 177-2514
200 6.40 (0.2520) 177-2515
6.50 (0.2559) 177-2516
6.60 (0.2598) 177-2517
6. Press lower bearing (10) and middle bearing (9) on the shaft.
7. Install the previously selected adjustment shim (8) .
8. Press upper bearing (7) on the shaft.
9. Measure the thickness of the snap ring (5). This is dimension (D) .
10. Install the snap ring (5) on the shaft.
11. Measure the distance between the top of the upper bearing and the top of the
snap ring. This is dimension (C) .
12. Take measured dimension (C) minus measured dimension (D). The result is the
thickness that is required for the shim.
dimension (C) - dimension (D) = required shim thickness.
Note: Dimension (C) must be 4.64-4.97 mm (0.1827-0.1957 in).
Table 34
Adjustment Shim (6)
200 2.60 (0.1024) 177-2491
2.65 (0.1043) 177-2492

2.70 (0.1063) 177-2493
2.75 (0.1083) 177-2494
2.80 (0.1102) 177-2495
2.85 (0.1122) 177-2496
2.90 (0.1142) 177-2497
2.95 (0.1161) 177-2498
14. Remove the snap ring.

15. Install the required shim and replace the snap ring.
Lift-Off Clearance Adjustment - A8VO
the barrel. The "lift-off" clearance, or the allowable separation can be adjusted.
The "lift-off" clearance or the allowable separation is adjusted by adding or
removing shims from the spring group in the center pin bore. Excessive leakage
will occur at high-pressure spikes which may lead to damage to the rotary group
and poor system performance if the allowable separation is too large.
Note: Perform calibration for each rotary group.
Typical lift-off clearance measurement

(12) Center pin
(13) Barrel
(14) Port plate
Required Equipment
372-6543 Gauge Plate
1. Insert the complete bearing assembly into the case with the center pin (12) and
the piston retaining plate (11) attached.
2. Properly seat the rotary group into the case bearing bore by using the press or
the extractor device.
3. Select the correct gauge plate from Table 35 to use from the kit 149-4935 Pump
and Motor Measuring Group .
Table 35
Gauge Plates
Piston
Displacement in cc Gauge plate part Gauge Plate Thickness mm
Diameter
number (in)
mm (in)
25 107 372-6543 9.10

(0.9842) (0.3583)
28.7 160 272-1417 9.62

(1.1300) (0.3787)
30.8 200 372-6544 12.20

(1.2125) (0.4803)
4. Place three 149-5141 gauge balls in the top of the gauge plate.
Note: "TOP" is engraved on the gauge plate.
5. Press the balls gently in the gauge plate.
Note: Do not press the balls completely in the gauge plate. Only press firm
enough to hold the balls in position.
Note: The lead balls vary in size. The lead balls must protrude from the gauge
plate at least 2.10 mm (0.0827 inch) prior to Step 6 in order to ensure proper
compression of the lead balls.
6. Place a small amount of grease on the top side of the gauge plate to help retain
the balls.
7. Place the gauge plate and the balls with the "TOP" side first into the barrel. The
grease should hold the gauge plate in place.
8. Install the cylinder barrel (13) on the center pin.
Note: Do not drop the barrel onto the center pin. This will lead to premature
crushing of the lead balls.
10. Tighten all head bolts to the specified torque while the pump shaft is turning.
Note: The pump shaft must be rotated while tightening bolts in order to seat all
components.
11. Loosen and remove the head group and the port plate.
12. Remove barrel from center pin.
13. Carefully remove the gauge plate from the barrel.
14. Measure the thickness of the gauge plate and the flattened balls at each gauge
ball location. These dimensions are (X1), (X2), and (X3) .
Note: Repeat the procedure if the measurements of each of the three gauge
ball locations are not within 0.05 mm (0.002 in).
The gauge plate after removal from the barrel. The lead shot is compressed at each of the locations of the
three balls.
15. Take the average value of (X1), (X2), and (X3). Call this dimension (X) .
(dimension (X1) + dimension (X2) + dimension (X3) ) / 3 = dimension (X) .
16. Take calculated dimension (X) minus the required lift-off clearance (Z) from
Table 36 in order to find the required thickness of the shim.
dimension (X) - dimension (Z) = required shim thickness.
Table 36
Lift-Off Clearance
Displacement in cc Lift-off Dimension (Z) in (mm) (in)
107
0.300-0.500 (0.012-0.020 )
160
0.300-0.500 (0.012-0.020 )
200
0.300-0.500 (0.012-0.020 )
(J) The shim thickness for A8VO 107/160/200
17. Select appropriate shim (15) in Table 37.

Note: Use only one shim for adjustment of lift-off clearance.
Table 37
Adjustment Shim
9T-3391
9.55 mm (0.3760 inch)
9T-3392
9.65 mm (0.3799 inch)
9T-3393
9.75 mm (0.3839 inch)
107 9T-3394
9.85 mm (0.3878 inch)
9T-3395
9.95 mm (0.3917 inch)
9T-3396
10.05 mm (0.3957 inch)
9T-3397
10.15 mm (0.3996 inch)
9.75 (0.3839) 5I-8405
9.85 (0.3878) 5I-8406
9.95 (0.3917) 5I-8407
10.05 (0.3957) 5I-8408
160 10.15 (0.3996) 5I-8409
10.25 (0.4035) 5I-8410
10.35 (0.4075) 5I-8411
10.45 (0.4114) 5I-8412
10.55 (0.4154) 8I-8413
200 12.30 (0.4843) 177-2509
12.40 (0.4882) 177-2508

12.50 (0.4921) 177-2507 (1)
12.60 (0.4961) 177-2506
12.70 (0.5000) 177-2505
12.80 (0.5039) 177-2504 (1)
12.90 (0.5039) - (1)
13.00 (0.5039) - (1)
13.10 (0.5039) - (1)
13.20 (0.5039) - (1)
13.30 (0.5039) - (1)
13.40(0.5039) - (1)
(1)
Included in 247-8851 Spacer Kit
18. Reassemble the pump with the appropriate adjustment shim.

A11VO/A11VLO
Lift-off Clearance Adjustment - A11VO/A11VLO
adding or removing shims from the center springunder the ball joint. Excessive
leakage will occur at high-pressure spikes which may lead to rotary group
damage and poor system performance if the allowable separation is too large.
Typical A11VO pump

(2) Ball joint
(3) Adjustment shim

(4) Spring group
(5) Barrel
(6) Port Plate
Required tooling

(2) Ball joint
(5) Barrel
(6) Port Plate
(7) Measuring bell
(8) Test ring or pins (3)
(9) Measuring hub

(10) Alignment plug
1. Select proper tooling from Table 38.
Table 38
Piston Hub (9) Bell (7) Test ring ( Test pins

Disp. Plug (10) Additional
diameter in Pt. No. Pt. No. 8) Pt. No. (8) Pt. No.
in cc Pt. No. Shim
mm (in)
129- 128- 128-2746 128-

130 - 6E-0721
24.8 (0.976) 3874 2744 2742
129- 1238- 128-2746 437-

145 - 6E-0721
26.1 (1.03) 3874 2744 5508
137- 129- 137-1329 (1)

137-
190 - -
28 (1.106) 1326 3876 1331
129- 129- 129-3880 129-

29.55 (1.163) 200 - -
3875 3876 3903
130- 129- 129-3881 129-

250 - -
31.8 (1.252) 9890 3876 3904
171- 129- 171-1112 (1)

171-
260 - -
31.2 (1.220) 1113 3876 1114
(1)
Three 137-1329 Test Pins are needed.
2. Place the port plate (6) on the surface plate. The flat side of the port plate (6)
must be facing downward.
3. Install the alignment plug (10) into the port plate center bore. The chamfer side
of alignment plug (10) must be facing upward.
4. Place the barrel (5) on the port plate and the alignment plug.
5. Place the test ring (8) or test pins (8) on the barrel in place of springs.
Note: The 190cc and 260cc pumps require the use of three test pins in place of
the test ring. Place the three test pins around the outside diameter of the
barrel's center pin bore. The three test pins must be equally spaced around the
barrel's center pin bore.
6. Install the ball joint (2) over the test ring pins on the barrel.
7. Place the piston retaining plate (1) over the ball joint.
8. Bolt tool (7) and tool (9) together. Place the tool (7) and the tool (9) on the
barrel. Refer to Illustration 37.
9. Measure dimension (A) by measuring the distance from the surface plate to the
top of the measuring bell.
10. Dimension (B) is scribed on the tool (7) .
11. Measured dimension (A) minus dimension (B) yields dimension (C) .
dimension (A) - dimension (B) = dimension (C)
Note: Do not measure the distance from the surface plate to the top of the
piston retaining plate in place of dimension (C). The piston retaining plate may
not be square with the surface plate, and the measurement will not be accurate.
12. Take the required lift-off clearance (D) from Table 39 minus the calculated
dimension (C) in order to find the required thickness of the shim (3).
dimension (D) - dimension (C) = required shim thickness.
Table 39
Lift-Off Clearance
Displacement in cc Dimension (D) in (mm) (in)
130 136.75-136.95 (5.3839-5.3917)
145 136.75-136.95 (5.3839-5.3917)
190 146.1-145.85 (5.75195-5.7421)
200 149.30-149.50 (5.8780-5.8858)
250 160.75-160.95 (6.3287-6.3366)
260 170.95-171.20 (6.7303-6.7402)

Note: 130cc and 145cc pumps use one shim and one additional shim if needed
for adjustment of lift-off clearance. This is shown in Table 38.
Note: 190cc, 200cc, 150cc and 260cc pumps use the appropriate shims as
shown in Table 40 in order to meet measurement (C) in Step 12.
Table 40
Adjustment Shim (3)
Shim thickness is mm (in)

Displacement in cc Part Number
130 0.70 (0.0276) 6E-0723

0.90 (0.0354) 6E-0721
1.10 ((0.0433) 6E-0720
1.30 (0.0512) 6E-0722
1.50 (0.0591) 6E-0724
0.70 (0.0276) 6E-0723
0.90 (0.0354) 6E-0721
145 1.10 ((0.0433) 6E-0720
1.30 (0.0512) 6E-0722
1.50 (0.0591) 6E-0724
0.50 (0.0197) 179-6915

190
0.075 (0295) 179-6914
0.60 (0.0236) 5I-4271
0.08 (0.0315) 5I-4270

200
1.00 (0.0394) 5I-4269
1.20 (0.0472) 5I-4268
0.60 (0.0236) 6E-3844
0.08 (0.0315) 6E-3843

250
1.00 (0.0394) 6E-3842
1.20 (0.0472) 6E-3841
0.50 (0.0197) 165-9361

260
0.75 (0.0295) 165-9362
14. Remove the tooling and install the appropriate shim between the barrel and
the spring group.
A20VLO
Note: The A20VLO adjustment of the rotary group procedure for the bearing
preload and the lift-off clearance adjustment uses the same procedure as the
A11VO/A11VLO.
Note: Perform calibration for each rotary group.
Rotation is counterclockwise when seen from drive end.

Type of pump: Vane.
For test, use SAE 10W oil at 150° (65°C).
Large Section Of The Pump (Shaft End)

Test at Full Speed:
Output ... 34.5 U.S. gpm(130.6 liter/min)
at a pressure of ... 100 psi(690 kPa)
with pump at ... 2080 rpm
with engine at ... 2000 rpm
Output ... 32.9 U.S. gpm (124.5 liter/min)

at a pressure of ... 1000 psi (6900 kPa)
Test at Half Speed


Small Section Of The Pump (Cover End)

Test at Full Speed

Test at Half Speed


(1) Torque for bolts (four) ... 45 ± 5 lb. ft.(60 ± 7 N·m)

(2) Torque for bolts ... 70 ± 5 lb. ft.(95 ± 7 N·m)

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Disassemble Dozer Control Valve

4. Carefully remove spool valve (7) from valve body.

7. Remove spring (14) and valve (15).

Assemble Dozer Control Valve

6. Install shuttle valve (39) and resolver valve (40) in body.

Disassemble Pilot Valve Group

1. Remove three bolts (2) from valve body (1).

Assemble Pilot Valve Group

Disassemble Ripper Control Valve

2. Remove six bolts (5) and separate the valve groups.

4. Remove spool (9).

Assemble Ripper Control Valve

Disassemble Hydraulic Tank

Assemble Hydraulic Tank

Remove Hydraulic Tank

This operation location is in the Operator's Station Disassembly And Assembly

6. Disconnect five hoses (2) from the hydraulic tank.

Install Hydraulic Tank

This operation location is in Operator's Station Disassembly And Assembly

1. Remove cap (1) from the hydraulic tank.

9. Use tool (A) to remove ring (14) from tube (15).

13. Remove cover (19) from bolt (7).

22. Remove seal (39) from block (37).

24. Remove seal (41) from base (40).

26. Remove tube assembly (42) from the tank.

31. Remove retainer (48) from the cover.

Assemble Hydraulic Tank

1. Install glass (1) and grommet (2) in retainer (3).

8. Install seal (15) in block (14).

11. Install seal (21) in tube (19).

22. Install spacer (38) and seal (39) on bolt (40).

23. Install cover (41) on bolt (40).

27. Put seal (43) in position on cover (41).

32. Install cap (52) on the filler tube.

This Operation Is In Operator's Station Disassembly And Assembly Section.

1. Disconnect four hoses (1) from the pressure control valve.

2. Remove two bolts (2) and pressure control valve (3).

Install Pressure Control Valve

This Operation Is In Operator's Station Disassembly And Assembly Section.

Disassemble Pressure Control Valve

Assemble Pressure Control Valve

5. Install O-ring seals (13) in cover (14).

(1) 2J6089 Spring for tilt relief valve:

(12) 9J5498 Spring for dump valve (outer):

Install Brake Hydraulic Mechanism And

Disassemble Brake Hydraulic Mechanism And

Cover (3) holds spring (5) under compression.

3. Remove slug (8) from valve spool (4).

Retaining ring (12) holds spring (10) under compression.

Assemble Brake Hydraulic Mechanism And

4. Install slug (6) in valve spool (5).

2. Remove flanges (1) and (3).

Install Steering clutch/">Clutch Hydraulic Control

Remove Steering clutch/">Clutch Hydraulic Control

Install Steering clutch/">Clutch Hydraulic Control

Remove Steering clutch/">Clutch Hydraulic Control

Install Steering clutch/">Clutch Hydraulic Control

4. Connect oil line (7) to the tee fitting.

6. Connect oil line (11).