Parker PGP 500 Series User manual

Pump & Motor Division
Vocational Truck Pump Program Catalog
Pump & Motor Division
PGP/PGM 500 Series
Service Manual

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Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL
INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by
usershaving technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product
catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specications, designs, availability and pricing, are subject to change by Parker Hannin Corporation and
its subsidiaries at any time without notice.
WARNING — User Responsibility
Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed
by the provisions stated in the “Offer of Sale”.
© Copyright 2020, Parker Hannin Corporation, All Rights Reserved

II III
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Table of Contents
General Information ...........................................................................................................................1-4
Single Pump........................................................................................................................................ 1
Use Genuine Parker Replacement Parts ......................................................................................... 2
Tool List ............................................................................................................................................... 3
Seal Installation Tools ........................................................................................................................ 4
Exploded View ....................................................................................................................................... 5
Bill of Materials...................................................................................................................................... 6
Disassembly Instructions ................................................................................................................7-10
Assembly Instructions ...................................................................................................................11-17
Guidelines of Acceptable Wear.....................................................................................................18-19
Fluid Recommendations................................................................................................................20-22
Start-up Procedure / Test Procedure ................................................................................................ 23
Offer of Sale ....................................................................................................................................27-28

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Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Single Pump
Aluminum
Gear Housing
Pressure
Balanced
Bushing
Block
Cast Iron Port End Cover
Case Hardened Gears
Low Friction Bushing Material
Aluminum or
Cast Iron Mounting
Flange
2 or 4-Bolt
Side and Rear Ports
Gear
Housing
Port End Cover
Mounting Flange
Shaft / Lip
Seal
INLET
CW
ROTATION
OUTLET
General Information

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Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Use Genuine Parker Replacement Parts
These service instructions will familiarize you with Parker's single and multiple pumps, their component parts, the relative
position of each part proper methods for assembly or disassembly of the units.
To facilitate the repair of these units, and before any work is done, we suggest that you rst read all of the steps used in
disassembly and assembly.
Dirt is the enemy of any hydraulic system. The rst requirement of good maintenance of hydraulic equipment is cleanliness.
MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN A CLEAN AREA.
The pictures show Model PGP511. Notes in the text cover variations between this unit and the other models.
It is important to airblast all parts and wipe them with a clean, lintless cloth before assembly.
USE CAUTION IN GRIPPING ALL PARTS IN THE VISE TO AVOID DAMAGING MACHINED SURFACES
A pump must be driven in the direction of rotation for which it was built; otherwise, the pressure will blow the shaft seal.
Check the exploded view and notes at right for proper direction of rotation.
Parker’s Replacement Parts
Parker’s replacement parts are of original equipment standards. For assured quality of material and work manship, and for
compatibility in assembly, USE ONLY GENUINE PARTS.
Check all replacement parts before installing them to be certain that they were not damaged in shipment.
General Information

3 4
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Tool List
Arbor press Snap ring pliers
Awl Prick punch
Clean, lintless cloths Scale (1/32" or 1/64" graduations)
Deburring tool (an old le with cutting teeth ground off) Small screw driver
Machinist’s hammer Torque wrench
Soft hammer Vise with 6" minimum opening
Medium grit carborundurn stone Bar for lip seal installation
Seal removal tool (See A) Special mylar sleeve (See B)
Oil and Grease
Special Mylar Sleeve
The special mylar sleeve is used to insert the drive shaft through the lip seal without damage. The drawing and chart
give details for making this special tool.
NOTE: Please see tool list for lip seal bar installation.
Pump/Motor A B C
PGP/PGM 505 2.71"-3.190" 0.631"-0.634" 0.634"- 0.635"
PGP/PGM 511 2.940"-3.000" 0.690"-0.694" 0.698"-0.702"
B
Seal Removal Tool
Easily made from an old screw driver. Heat the tip and bend as shown. Grind the tip to t the notch behind the shaft
seal.
A
1/4"
General Information
A Length
B
I.D.
C
O.D.

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Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
General Information
Pump/Motor SEC Description A B C D E F G H
PGP/PGM 505 A1, A2 Integral Shaft 0.946" 3.500" 0.630" 0.275" 0.748" 0.040" 30° 0.060"
PGP/PGM 505 L5 Continental
Shaft 1.024" 3.500" 0.630" 0.275" 0.748" 0.040" 30° 0.060"
Pump/Motor SEC Description A B C D E F
PGP/PGM 511 H2 Integral Shaft 0.786" 1.368" 0.295" 0.974" 0.500" 3.250"
PGP/PGM 511 H3 Integral Shaft 0.786" 1.368" 0.295" 0.516" 0.500" 4.000"
Pump/Motor SEC Description A B C D E F G
PGP/PGM 511 L2 Continental Shaft 1.800" 1.400" 1.750" 2.000" 3.200" 8.250" 0.750"
PGP/PGM 511 L3 Continental Shaft 1.800" 1.400" 2.500" 2.750" 3.200" 8.250" 0.750"
B
F
D
H
G
Polish this end
EC
A
F
BA
C
D E
A
B
G
C
F
E
D
Seal Installation Tools
Constructed from mild steel

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Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Catalog HY13-PMD500-SM/US
Exploded View
1
2
3
9
6
5
4
11
12
13
3
12
13
8
4
5
6
7
9
10

5 6
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Catalog HY13-PMD500-SM/US
Bill of Materials
ITEM DESCRIPTION QTY.
1 Lip Seal 1
2 Mounting Flange 1
3 Dowel Pin 2
4 Backup Seal 2
5 Channel Seal 2
6 Thrust Block 2
7 Drive Gear 1
8 Driven Gear 1
9 O-Ring Seal 2
10 Gear Housing 1
11 Port End Cover 1
12 Washer 4
13 Capscrew 4

7 8
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Disassembly Instructions
1) Place the pump in a vise with the drive shaft pointing
down (Fig. 1). Match-mark all sections. Be sure to align
these marks when reassembling.
DO NOT GRIP ON OR NEAR ANY MACHINED
SURFACES DURING ASSEMBLY OR DISASSEMBLY.
Start Disassembly
CAUTION:
1. If prying off sections becomes necessary, take extreme care not to mar or damage machined surfaces. Excessive force
while prying can result in misalignment and seriously damage parts.
2. If parts are difcult to t during assembly, tap gently with a soft hammer. (Never use an iron hammer.)
3. Handle with care to avoid damage to the journals or teeth. Avoid touching gear journals.
2) Remove four bolts and cap screws on single units
or the 4 hex nuts, studs and washers of multiple
units (Fig. 2). Use an impact driver in a cross-
pattern. Inspect threads and cap screws for wear.
3) Lift off the port end cover and look at underside
for any damage (Fig. 3). If prying is necessary, be
careful not to damage the machined surfaces.
Figure 1
Figure 2
Figure 3

7 8
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
4) Remove gear housing (Fig. 4). If prying with
screwdriver is necessry, be careful not to damage
the machined surfaces.
Example of excessive cutout on a gear housing,
circled in yellow. (Fig. 5).
5) Mark bushing blocks top and bottom. Remove thrust
plate. (Fig. 6). Examine and replace if necessary. See
wear guide page 18.
Figure 4
Figure 5
Figure 6
Below are some examples of damaged plates (Fig. 7):
Disassembly Instructions
Figure 7

9 10
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Disassembly Instructions
7) Carefully remove idler gear rst. (Fig. 9). Avoid tapping
the gear teeth together or against other hardened
surfaces.
6) Before removing gears, draw a match mark in
center of the gear teeth. (Fig. 8). Doing so will help
make sure they are placed back in the correct
position when reassembling the pump.
8) Next, remove the drive gear (Fig. 10). Keep these
gears together because they are a matched set.
Examine each for wear and replace if necessary.
See wear guide on page 18.
9) Carefully remove the thrust block from the bottom
of body (Fig. 11). Inspect all bushings in thrust
block for scoring or discoloration and replace if
necessary.
Figure 8
Figure 9
Figure 10
Figure 11

9 10
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Disassembly Instructions
10) If equipped, remove the snap ring (Fig. 12).
Snap ring is located in front of the shaft seal.
Figure 12
11) Pry out the lip seal (Fig. 13). Be careful not to damage
seal bore in pump body.
See tool list on page 3 for prying device.
Figure 14
Figure 13
12) Remove, replace section seal and examine for
debris or wear. (Fig. 14).
When replacing the seal, grease thoroughly
and insert rmly into the gear housing before
reassembling. Contact an authorized Parker
Service Center to determine and order the proper
seal kit for your pump.

11 12
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
1) Before start, clean all machined surfaces and make
sure are free of debris.
2) Prep new lip seal for replacement (Fig. 1).
3) Grease new lip seal (Fig. 2). Coat the outer edge
of the lip seal and its recess with non-hardening
sealant or equivalent before replacing.
4) Replace lip seal (Fig. 3 & 4).
With the metal side of
the lip seal up, press it into the mounting ange side
of the shaft end cover with an arbor press and bar
(see Tool List on page 3). Be careful not to damage
the lip of the seal.
Press in until ush with the recess. Wipe off excess
sealant.
Start Assembly
Figure 1
Figure 2
Figure 3
Figure 4

11 12
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
5) Replace bearing (Fig. 5). Place new bearing over lip
seal for installation.
6) Press new bearing over lip seal (Fig. 6 & 7) .
Using arbor press, seat new bearing ush with lip
seal.
Figure 5
Figure 6
Figure 7

13 14
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
Figure 9
Figure 10
Figure 11
9) Re-afx or replace section seal (Fig. 11) . Verify both
sides of the section seal are free of debris. If need
to replace, grease the new section seal and insert
rmly into the grooves in both sides of the gear
housing.
Figure 8
8) Mount shaft end cover facing down in a vise
(Fig. 10) .
7) Assemble the snap ring (Fig. 8 & 9) . Using snap ring
plyers, seat new snap ring on top of bearing and lip
seal.

13 14
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
Figure 12
Figure 13
10) Install gear housing (Fig. 12) .
Be sure to line up witness marks as press down.
11) Assemble new sealing parts in thrust block and
verify orientation (Fig. 13) .

15 16
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
The sealing parts can be xed with grease. (see below for steps to install sealing parts correctly)
i. Turn the thrust blocks so the seal groove faces up
ii. Place the soft black into the seal groove with the at side down
iii. Place the hard nylon back-up seal, at side up, into the groove on top of the rubber seal
Pump Thrust Block - Back Side (Fig. 14) & (Fig. 15)
Pump Thrust Block - Front Side (Fig. 16)
Motor Thrust Block - Back Side (Fig. 17) & (Fig. 18)
Motor Thrust Block - Front Side (Fig. 19)
The proper seal installation is very important. If these seals are assembled upside down, they will most likely
fail in a short period of time under system pressure.
Figure 14
Pump Thrust Block - Back Side
Figure 15 Figure 16
Pump Thrust Block - Front Side
Figure 17
Pump Thrust Block - Back Side
Figure 18 Figure 19
Pump Thrust Block - Front Side

15 16
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
Figure 20
Figure 22
Figure 23
12) Assemble the front thrust block into port end
cover (Fig. 20).
Orientation is rotation sensitive for pumps and
the seals should be pointed down and facing the
high pressure side of the pump, the pressure port.
Push down until thrust block is ush with the shaft
end.
13) Insert drive gear (Fig. 21).
Use a lubricated seal guide, slide over the drive
gear to protect teeth during assembly. Insert shaft
fully through port end cover until seal guide falls
through the underside and drive gear is seated
rmly at the bottom of port end cover.
Example of a shaft seal guide protecting a gear
(Fig. 22).
14) Insert idler gear (Fig. 23). Push through trust block
and port end cover, making sure to line up the
witness marks.
Figure 21

17 18
Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC Parker Hannifin Corporation |Pump & Motor Division |Kings Mountain, NC
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
WARNING: This product can expose you to chemicals including lead or DEHP which are known to the state of California to cause cancer,
birth defects, and other reproductive harm. www.p65warnings.ca.gov
Catalog HY13-PMD500-SM/US PGP/PGM 500 Series
Gear Pumps & Motors Service Manual
Assembly Instructions
Figure 24
Figure 25
Figure 26
500 Series Torque Guide
Series Lbs-ft
PGP502/PGM502 15
PGP505/PGM505 22.5
PGP511/PGM511 36
PGP517/PGM517 83
Figure 27
15) Install top thrust block (Fig. 24). Use grease to
hold into groove. Then, place rear thrust block
over top of gears. It is important that the pressure
plate be installed with inlets pointing toward
discharge side.
17) Install hardware (bolts and washers) (Fig. 26).
Thread the fasteners into the port end cover and
tighten in a cross pattern, rst by hand then with
an impact tool.
18) Torque fasteners in cross-pattern (Fig. 27).
Do not lubricate fastener threads before assembly.
Follow below torque guide.
16) Install port end cover. (Fig. 25). Be sure to line up
witness marks.