G1-G2-H2 Transmission Manual - The Grasshopper...

G1 - G2 - H2TRANSMISSIONS

SERVICE MANUAL

THE GRASSHOPPER COMPANYMoundridge, Kansas 67107 U.S.A.

Phone (620) 345-8621Fax (620) 345-2301

Rev. 09-16Form 172120

Printed in U.S.A

Price $24.00

Copyright © 2016, 2013, 2012, 2011, 2010, 2006, 2004 by The Grasshopper Company. The following material is proprietary information. All rights reserved. Reproduction or dissemination in any form by any means is prohibited, except by express written permission from The Grasshopper Company.

2

Introduction

The purpose of this manual is to provide helpful information in maintaining, trouble-shooting, and servicing Grasshopper pump and wheel motor drives, in addition to providing part number identifi cation. For best results out of the manual you need to read the entire text before beginning any work on these components. If you need further assistance, contact Grasshopper Technical Support.

3Rev. 12-04

TABLE OF CONTENTSWHEEL MOTORS P A G E Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tools Required for Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassembly & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 Rotor Set Component Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Wheel Motor Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Wheel Motor Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-33

HYDRO PUMPS Introduction/ Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Tools Required for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 BDP-10L Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 BDP-10A & BDP-16A Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 BDP-21L Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 H1A-12 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 BDP-10L Pump-Service & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50 Purging of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 BDP-10L Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 BDP-10A/BDP-16A/BDP-21L-Servicing & Repairing . . . . . . . . . . . . . . . . . . . . . . 54-66 BDP-10A Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 PK-12 Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 BDP-16A Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 BDP-21L Breakdown & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 H1-10 Breakdown & Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 H1A-12 Breakdown & Parts List.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 72 H3-10 Breakdown & Parts List. . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 73 H4-12 Breakdown & Parts List. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

G1 AND G2 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-77

HYDRO PUMP FLOW TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-79

G1/G2/H1/H2 PUMP & MOTOR APPLICATION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-82

TRANSMISSION MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .83

5Rev. 7-13

WHEEL MOTORSTroubleshooting Guide

Preliminary ChecksHydraulic systems are often trouble-free, once you have determined that a problem exists, startwith the easy-to-check items, such as:

• Mechanical linkage problems such as binding, broken or loose parts or slipping belts.

• Check all hoses and lines for cracks, hardening or other signs of wear. Reroute any usable hoses that are kinked or severely bent. Look for leaks, especially at couplings and fi ttings.

• Visually check other components to see if they are loosely mounted, show signs of leaks or other damage or wear.

Tools and Materials Required for Servicing• Clean, petroleum-based solvent• Emery paper• Vise with soft jaws• Air pressure source• Arbor press• Torque wrench-ft. lbs.• Socket: 9/16 inch thin wall• Adjustable crescent wrench or hose fi tting wrenches• Feeler gage .005 (.13mm)• Special Bearing Mandrel (Grasshopper PN 885288)• Blind hole bearing puller for 1.400 inch dia. (35.6mm) and 2.130 inch dia. (54.1 mm) bearings

Disassembly and Inspection(Preparation Before Disassembly)• Thoroughly clean off all outside dirt, especially from around fi ttings and hose connections, before

disconnecting and removing the wheel motor. Remove rust or corrosion from coupling shaft.• Remove hose fi ttings and immediately plug port holes and fl uid lines.• Remove wheel motor from unit, drain it of fl uid and take it to a clean work surface.• Clean and dry the motor before you start to disassemble the unit.• As you disassemble the motor, clean all parts except seals in clean petroleum-based solvent, and

blow them dry.

Warning: Petroleum-base solvents are fl ammable. Be extremely careful when using any solvent.

• Keep parts separate to avoid nicks and burrs.• Discard all seals and seal rings as they are removed. Replace all seals, seal rings and any dam-

aged or worn parts.

6Rev. 12-04

1) Place the motor in a soft jawed vice, with the coupling shaft (12) pointed down and the vise jaws clamping fi rmly on the sides of the housing (18) mounting fl ange. Figure 1

2) Scribe an alignment mark down and across the motor components from end cover (2) to housing (18) to help when reas-sembling. Figure 1 3) Remove the seven special ring head bolts (1) using a 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Figures 2 & 3

WARNING: If the motor is not fi rmly held in the vise, it could be dislodged during the service procedures, causing injury.

Figure 1

Figure 2

Figure 3

7Rev. 12-04

4) Remove end cover assembly (2) and seal ring (4). Discard seal ring. Figure 45) Thoroughly wash end cover (2) in proper solvent and blow dry. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces.

NOTE: A polished pattern (not scratch-es) on the cover from rotation of the commutator (5) is normal.

Figure 4

6) Remove commutator ring (6). Inspect commutator ring for cracks or burrs. Figure 57) Remove commutator (5) and seal ring (3). Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear and scoring. Figure 6 & 7

Figure 5

Figure 6 Figure 7

8Rev. 12-04

8) Remove manifold (7) and inspect for cracks or surface scoring. A polished pattern on the ground surface from commutator or rotor rota-tion is normal. Remove and discard the seal rings (4) that are on both sides of the manifold (7). Figure 8

NOTE: The manifold is constructed of plates bonded together to form an inte-gral component not subject to further disassembly for service. compare con-fi guration of both sides of the manifold to ensure that the same surface is reas-sembled against the rotor set.

9) Remove rotor set (8) and wear plate (9) together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. Figure 9 The drive link (10) may come away from the coupling shaft (12) with the rotor set and wear plate. You may have to shift the rotor set on the wear plate to work the drive link out of the rotor (8A) and wear plate. Inspect the rotor set in its assembled form for nicks, scoring or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Discard seal ring (4) that is between the rotor set and wear plate.

NOTE: The rotor set (8) components may become disassembled during service proce-dures. Marking the surface to the rotor and stator that is facing up, with etching ink or grease pencil before removal from motor will ensure correct reassembly of rotor into sta-tor and rotor set into motor. Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of the rotor set.

Figure 8

Figure 9

9Rev. 12-04

10) Place rotor set (8) and wear plate (9) on a fl at surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gauge at this common centerline. If there is more than .005 inches (0.13mm) of clearance, re-place rotor set. Figure 1011) Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing. Figure 1112) Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear or corrosion and a full complement of retained rollers. Figure 1213) Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and cor-rosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fi ne emery paper may be used. Figure 13

Figure 10

Figure 11

Figure 13Figure 12

10Rev. 12-04

14) Remove coupling shaft (12) , by pushing on the output end of shaft. Figure 14Inspect coupling shaft bearing and seal sur-faces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal splines and external keyway. Figure 15Replace coupling shaft if any of these condi-tions exist.

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.151mm) diametrically, replace coupling shaft. A slight "polish" is permissible in the shaft bearing areas. Anything more would require coupler shaft replacement.

15) Remove and discard seal ring (4) from housing (18).16) Remove inner coupling shaft bearing (13), using a blind-hole bearing puller. Once the bearing is pulled out you can remove the two thrust washers with thrust bearing. Figure 16

Figure 14

Figure 15

Figure 16

Inspection Areas

11Rev. 12-04

17) Remove seal (16), and the two backup washers (17 & 21) by working them around un-seated thrust washers and thrust bearing and out of the housing. Discard seal and washers. Figure 18

NOTE: The depth or location of the bear-ing (13) in relation to the housing wear plate surface and the depth or location of the bearing (19) in relation to the begin-ning of the bearing counter bore should be measured and noted before removing the bearing. This will facilitate the correct reassembly of the new bearing . Figure 17

NOTE: The inner coupling shaft bearing (13) does not need to be removed to re-move the seal (16) and two backup wash-ers (17 & 21).

18) Remove housing (18) from vise, invert it and remove and discard seal (20), then remove outer coupling shaft bearing by using a blind hole bearing puller. Figure 19

Figure 17

Figure 18

Figure 19

12Rev. 12-04

Assembly

• Replace all seals and seal rings with new ones each time you reassemble the wheel motor. Lu-bricate all seals and seal rings with SAE 10W-40 oil or clean grease before assembly.

• NOTE: Individual seals and seal rings as well as a complete seal kit are available.• NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.• Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with com-

pressed air.

1) If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing (19) with clean corrosion resistant grease. Press the new bearing into the counterbore at the mounting fl ange end of the housing, using the appropri-ate sized bearing mandrel, (Grasshopper PN 885288) which will control the bearing depth. These housings require the use of the bear-ing mandrel to press the bearing (19) into the housing to a required depth of .290/.310 inches (7.37/7.87 mm) from the outside end of the bearing counterbore. Figure 20

NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing is not cocked when pressing the bearing into the housing.

CAUTION: If the bearing mandrel speci-fi ed is not available and alternate meth-ods are used to press in the outer and inner coupling shaft bearings (13 & 19) as specifi ed. The specifi ed depths must be achieved to insure adequate bearing sup-port and correct relationship to adjacent components when assembled. Figure 21

CAUTION: Because the inner and outer coupling shaft bearings (13 & 19) have a press fi t into the housing, they must be discarded when removed. They must NOT be reused.

Figure 20

Figure 21

13Rev. 12-04

2) It is recommended that when you reas-semble the wheel motor that you use a new backup washer (17), new backup washer (21), new seal (16), with the lip facing to the inside of the motor, new thrust washer (14), new thrust bearing (15) and a new second thrust washer (14) in that order before pressing in the inner housing bearing (13). Figure 22 & 23 When these components are in place press the new bearing (13) into the housing to a depth of .105/.125 inches (2.67/3/18 mm). Use the opposite end of the bearing mandrel used to press in the outer bearing (19). Figure 243) Press the new dirt and water seal (20) into the housing until the seal is fl ush to .020 inches (.51 mm) below the end of the housing (18). Figure 254) Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting fl ange.

16

21

17

14

15

14

Figure 22

Figure 23

Figure 25Figure 2414

Rev. 12-04

5) If the motor housing (18) did not require replacement of the inner roller bearing, it will require that the two "captured" thrust washers (14) and thrust bearing (15) be unseated and vertical to the counterbore and the new backup washer (17), new backup washer (21), and new seal (16) be worked around the thrust bear-ing package and placed into their respective counterbores. The seal lip must face out of the seal counterbore and toward the inside of the motor. Be sure the thrust bearing assembly is reseated correctly after assembly of the seal and backup washer. Figure 266) Apply masking tape around the keyway on the shaft (12) to prevent damage to the seal. Figure 277) Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing (19). Install the coupling shaft (12) into the housing (18), seating it against the second thrust washer (14). Figure 28

CAUTION: The outer bearing (19) is not lubricated by the system's hydraulic fl uid. Be sure it is thoroughly packed with the recommended grease.

Figure26

Figure 27

Figure 28

NOTE: Be sure to remove masking tape after coupling shaft has been put into place.

15Rev. 12-04

NOTE: The tube of grease that comes with the seal kit is used for packing the outer bearing (19). If you do not have this, you can use Mobile Mobilith SHC 460.

NOTE: The coupling shaft (12) will be approximately .10 inch (2.54 mm) below the housing wear plate surface to allow the assembly of the thrust bearing. The coupling shaft must rotate smoothly on the thrust bearing package. Figure 29

8) Install thrust bearing (11) onto the end of the coupling shaft (12). Figure 309) Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. Figure 31

Figure 29

Figure 30

Figure 31

16Rev. 12-04

NOTE: One or two alignment studs screwed fi nger tight into the housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. the studs can be made by cutting off the heads of 3/8-24 UNF 2A as required that are over .5 inch (12.7 mm) longer than the bolts used in the wheel motor.

10) Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the cou-pling shaft splines. Figure 32

NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

11) Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). Figure 3312) Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator Figure 34

Figure 32

Figure 33

Figure 3417

Rev. 12-04

NOTE: It may be necassary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE: If necessary, go to the "Rotor Set Assembly Procedure." (See page 21)

13) Install the assembled rotor set (8B) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines. Figure 35

Figure 35NOTE: The rotor set rotor counterbore side must be down against the wear plate for drive link clearance and to maintain the original rotor drive link spline con-tact. The rotor set seal ring groove faces toward the wear plate (9).

NOTE: The manifold (7) is made up of several plates bonded together perma-nently to form an integral component. The manifold surface that must contact the rotor set has it's series of irregular shaped cavities on the largest circumfer-ence or circle around the inside diameter. The polished impression left on the mani-fold by the rotor set is another indication of which surface must contact the rotor set.

14) Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). Figure 36

Figure 36

15) Assemble the manifold (7) over the align-ment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. Figure 37

Figure 3718

Rev. 12-04

16) Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. Figure 3817) Assemble the commutator ring (6) over the alignment studs onto the manifold. Figure 3918) Assemble a new seal ring (3) fl at side up, onto commutator (5) Figure 40 and assemble commutator over the end of the drive link (10) onto manifold (7) with seal ring side up.Figure 41

Figure 41

Figure 39

Figure 40

Figure 38

19Rev. 12-04

19) Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. Figures 42 & 4320) Assemble the 7 special bolts (1) and screw in fi nger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other componenets into place with a fi nal torque of 45-55 ft. lbs. (61-75 Nm). Figures 44 & 45 Figure 42

Figure 43

Figure 45Figure 44

1

3

5

72

4

6

20Rev. 12-04

Rotor Set Component Assembly ProcedureA disassembled rotor, stator and vanes that cannot be readily assembled by hand can be assem-bled by the following procedure.

1) Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following wheel motor assembly procedures 1 through 13. Be sure the seal ring is in place. Figure 462) If assembly alignment studs are not being utilized align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) fi nger tight into bolt holes approximately 180 degrees apart to keep the stator and wear plate stationary.3) Assemble the rotor (8A) counterbore down, into stator (8B) and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. Figure 47

4) Assemble the seven vanes (8C) into the stator vane pockets. Figure 48

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

5) Grasp the output end of the coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into the stator (8B), creating the necessary clearance to assemble the seventh vane. Assemble the seventh vane using minimum force.6) Remove the two assembled bolts (1) if used to retain stator and wear plate.7) Go to wheel motor assembly procedure to continue assembly of wheel motor. (See page 18)

Final Check• Pressurize the wheel motor with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for

external leaks.

NOTE: If the manifold side of the rotor was etched during disassembly, this side should be up. If the rotor is not etched, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

Figure 46

Figure 47

Figure 48

21Rev. 12-04

22Rev. 03-16

WHEEL MOTOR APPLICATION GUIDEMODEL SERIAL NUMBER PARTS LIST

PAGE #120 / 120K / 124 ALL 23200 SERIES 5299999 & Below 24200 SERIES 5300000 - 5421820 25200 Series excluding 225V/48, 225V/52, 226V/48, 226V/52

For wheel motors serial number below 12112 0000 26

200 Series excluding 225V/48, 225V/52, 226V/48, 226V/52

For wheel motors serial number 12112 0000 & above 27

225V/48 & 225V/52 ALL 28226V/48 & 226V/52 ALL 28321D 5299999 & Below 24321D, 322D, 325D 5300000 & Above 29325A ALL 29325 5299999 & Below 30325, 329, 329B, 335 5300000 & Above 29325A, 327A, 327-EFI, 327KW ALL 29400 Series 5299999 & Below 30400 Series 5300000 & Above 31721D2 5299999 & Below 32721D2, 722D2 5300000 & Above 29718KH2, 723KH2, 721DH2 ALL 26721G2, 725K2, 725A ALL 29725G2 5299999 & Below 32725G2, 729G2 5300000 & Above 31727K2, 727A, 727KW ALL 29928D2, 932 5299999 & Below 33928D2, 932, 930D2 5300000 & Above 31

23 TE0195

Rev. 02-12

Item Order Description Item Order Description No. No. No. No.

1 HOUSING ASSEMBLY 2 130368 BEARING 3 130336 BEARING 4 130331 WEAR PLATE 5 COMMUTATOR RING 6 COMMUTATOR 7 130312 COMMUTATOR SEAL (HI-TEMP) 8 END COVER 9 130303 BACK UP RING 10 130347 THRUST WASHER 11 130304 BACK UP WASHER 12 MANIFOLD

13 130307 COUPLING SHAFT 14 281845 KEY 15 253992 NUT 16 130376 ROTOR ASSEMBLY 17 130313 DRIVE LINK 18 SPECIAL BOLT 19 130348 THRUST BEARING 20 130390 SEAL RING 21 130325 DIRT & WATER SEAL 22 130339 SHAFT SEAL 23 130388 SEAL KIT

23 SEAL KIT1

23

9 1011

1314

15

19

17

21

22

6

4

5

8

12

16

7

18

2020

20

20

20

TE0195

Torque to 25-30 Ft. lbs.


24MB1570

Rev. 02-12


1 HOUSING ASSEMBLY 2 130370 BEARING 3 130340 BEARING 4 130346 THRUST WASHER 5 130344 THRUST BEARING 6 130310 COUPLING SHAFT 7 130316 DRIVE LINK 8 COMMUTATOR RING 9 COMMUTATOR 10 130312 COMMUTATOR SEAL (HI-TEMP) 11 SPECIAL BOLT 12 130315 DIRT & WATER SEAL

13 281860 KEY 14 254522 NUT 15 130306 BACK-UP RING 16 130305 BACK-UP WASHER 17 130341 SHAFT SEAL 18 130386 SEAL RING (BUNA) 19 130330 WEAR PLATE 20 130342 THRUST BEARING 21 130380 ROTOR SET 22 MANIFOLD ASSEMBLY 23 END COVER 24 130385 SEAL KIT

1

2

3

45

8 910

11

12

13

14

1516

18

19 1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

MB1570



25 TF0240

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

1819

1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

TF0240



26TL0240

Rev. 03-16


1 HOUSING ASSEMBLY 2 130370 BEARING 3 130340 REAR RADIAL BEARING 4 130346 THRUST WASHER 5 130344 THRUST BEARING 6 130308 COUPLING SHAFT 7 130314 DRIVE LINK 8 COMMUTATOR RING 9 COMMUTATOR 10 130312 COMMUTATOR SEAL (HI-TEMP) 11 SPECIAL BOLT 12 130315 DIRT & WATER SEAL

13 281860 KEY 14 254522 NUT 15 130306 BACK-UP RING 16 130305 BACK-UP WASHER 17 130386 SEAL RING (BUNA) 18 130330 WEAR PLATE 19 130342 THRUST BEARING 20 END COVER 21 130378 ROTOR ASSEMBLY 22 130338 SHAFT SEAL (1.4 DIA) 23 MANIFOLD 24 130387 SEAL KIT

1

23

45

8 910

11

12

13

14

15 16

17

19

1721

22

6

7

17

18 17

23

24 SEAL KIT

17 20

TL0240



WHEEL MOTOR SERIAL NUMBERBELOW 12112 0000

27 TL0240-1

Rev. 03-16


1 HOUSING ASSEMBLY 2 130370 BEARING 3 130340 REAR RADIAL BEARING 4 130345 THRUST WASHER 5 130344 THRUST BEARING 6 130308 COUPLING SHAFT 7 130314 DRIVE LINK 8 COMMUTATOR RING 9 COMMUTATOR 10 130312 COMMUTATOR SEAL (HI-TEMP) 11 SPECIAL BOLT 12 130315 DIRT & WATER SEAL

13 281860 KEY 14 254522 NUT 15 130306 BACK-UP RING 16 130305 BACK-UP WASHER 17 130386 SEAL RING (BUNA) 18 130330 WEAR PLATE 19 130342 THRUST BEARING 20 END COVER 21 130378 ROTOR ASSEMBLY 22 130338 SHAFT SEAL (1.4 DIA) 23 MANIFOLD 24 130387 SEAL KIT

1

23

45

8 910

11

12

13

14

15 16

17

19

1721

22

6

7

17

18 17

23

24 SEAL KIT

17 20

TL0240-1



4

WHEEL MOTOR SERIAL NUMBER12112 0000 & ABOVE

28TJ0230

Rev. 02-12


1 HOUSING ASSEMBLY 2 130370 BEARING 3 130337 BEARING 4 130349 THRUST WASHER 5 130350 THRUST BEARING 6 130331 WEAR PLATE 7 130319 DRIVE LINK 8 COMMUTATOR RING 9 COMMUTATOR 10 130312 COMMUTATOR SEAL (HI-TEMP) 11 END COVER 12 MANIFOLD

13 130377 ROTOR ASSEMBLY 14 SPECIAL BOLT 15 130390 SEAL RING 16 130315 DIRT & WATER SEAL 17 130309 COUPLING SHAFT 18 281860 KEY 19 254522 NUT 20 130306 BACK UP RING 21 130305 BACK UP WASHER 22 130338 SHAFT SEAL 23 130389 SEAL KIT

1

23

45

89 10

11

12

1315

15

16

1718

19

2122

6

7

204

1515

14

15

23 SEAL KIT

TJ0230



29 TG0310

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

1819 18

21

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

TG0310



30MB0360

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

18

19 1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

MB0360



31 TF0360

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

1819

1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

TF0360



32ME2170

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

18

19 1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

ME2170



33 ME2470

Rev. 02-12




1

2

3

45

8 910

11

12

13

14

1516

18

19 1821

22

6

7

18

17

23

24 SEAL KIT

18

20

18

4

ME2470



HYDRO PUMPS

IntroductionWe use four different series of pumps on our units; BDP-10L, BDP-10A, BDP-21L and H1A-12. If you have to move the machine a short distance without operating the engine, a screw type bypass valve is utilized in the pumps to permit movement of the machine. The bypass valve is fully opened when unscrewed two (2) turns maximum. The bypass valve allows oil to be routed from one side of the pump circuit to the other, thus allowing the motor to turn with minimal resistance. The bypass valve must be fully closed during normal operation. Do not overtighten (see torque specifi cations, pages 26-29). Warning: Actuating the bypass will result in the loss of hydrostatic braking capacity. The machine must be stationary on a level surface and in neutral when actuating the bypass.

Troubleshooting

In many cases, problems related to "drive-ability" are not directly related to a defective pump but are caused by slipping belts, partially engaged bypass valves, and loose or damaged control linkages. Here is a troubleshooting chart to help you.

Symptom Probable Cause• Unit will not attain normal maximum speed. Engine not operating at correct speed.

Control linkage damaged or binding.

Bypass valve stuck; partially open. Charge check valve held open. (Problem in one direction only)

• Unit will not move when control lever is moved. Control linkage damaged or not con- nected.

Drive belt between engine and trans mission broke.

Transmission low on fl uid.

• Unit is jerky or operating erratically. Inlet air leak.

• Unit is "sluggish" under load. Loose drive belts between engine and (operates OK on level surface) transmission.

Transmission low on fl uid.

Water in transmission fl uid (evaporates when hot, resulting in low fl uid level)

34Rev. 12-04

Tools required for servicing

Misc.• Torque Wrench• Scribe, Paint Pen or Marker• Seal Hook• Flat Blade Screw Driver• Internal Snap Ring Pliers

Allen Wrenches• 5 mm• 6 mm• 3/16"• 1/4"

Sockets• 3/8" Drive Ratchet• 9/16"• 1/2"• 5/8"• 10 mm

Combination Wrenches• 9/16"• 1/2"• 5/8"• 7/8"• 10 mm

35 Rev. 12-04

Tightening Torques

BDP-10L

A. Case Drain (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-240 in-lb (15-20 ft. lbs.)B. System Port (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-240 in-lb (15-20 ft. lbs.)C. Inlet (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-120 in-lb (8-10 ft. lbs.)D. Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-240 in-lb (15-20 ft. lbs.)E. Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-120 in-lb (7-10 ft. lbs.)F. Charge Cover Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-120 in-lb (7-10 ft. lbs.)G. End Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-180 in-lb (10-15 ft. lbs.)

A

G

B C B

G

F

G

D

E

D

G

36Rev. 12-04

Tightening Torques

BDP-10A & BDP-16A

BDP-10A BDP-16A

A. Case Drain (fi tting torque) 200-250 in-lb (17-21 ft. lbs.) 200-250 in-lb (17-21 ft. lbs.)B. System Port (fi tting torque) 370-470 in-lb (31-39 ft. lbs.) 370-470 in-lb (31-39 ft. lbs.)C. Inlet (fi tting torque) 200-250 in-lb (17-21 ft. lbs.) 370-470 in-lb (31-39 ft. lbs.)D. Check Plug 180-240 in-lb (15-20 ft. lbs.) 180-240 in-lb (15-20 ft. lbs.)E. Bypass Valve 84-120 in-lb (7-10 ft. lbs.) 95-120 in-lb (8-10 ft. lbs.)F. Charge Cover Cap Screw 87-118 in-lb (7-10 ft. lbs.) 180-220 in-lb (15-18 ft. lbs.)G. End Cap Bolt 167-217 in-lb (14-18 ft. lbs.) 255-300 in-lb (21-25 ft. lbs.)H. Diagnostic Plug 84-120 in-lb (7-10 ft. lbs.) 85-120 in-lb (7-10 ft. lbs.)I. Shock Valve Cap 200-275 in-lb (17-23 ft. lbs.) 180-240 in-lb (15-20 ft. lbs.)J. Fan, Nut, Hex Lock 130-150 in-lb (11-13 ft. lbs.) 250-270 in-lb (21-23 ft. lbs.)

D

G

B H B

G

I

F

G

CE

G

A

F

37 Rev. 12-04

J

Tightening Torques

BDP-21L

A. Case Drain (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370-470 in-lb (31-39 ft. lbs.)B. System Port (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370-470 in-lb (31-39 ft. lbs.)C. Inlet (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370-470 in-lb (31-39 ft. lbs.)D. Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-240 in-lb (15-20 ft. lbs.)E. Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-120 in-lb (7-10 ft. lbs.)F. Charge Cover Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-275 in-lb (17-23 ft. lbs.)G. End Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-345 in-lb (21-29 ft. lbs.)H. Diagnostic Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-120 in-lb (7-10 ft. lbs.)I. Fan, Nut, Hex Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250-270 in-lb (21-23 ft. lbs.)

D

G

B H B

G

D

F

G

C

E

G

A

F

38Rev. 12-04

I

H1A-12

Tightening Torques

39Rev. 12-04

Case Drain (fi tting torque) (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . 160-200 in-lb (13-17 ft. lbs.)B. System Port (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370-470 in-lb (31-39 ft. lbs.)C. Inlet (fi tting torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-200 in-lb (13-17 ft. lbs.)D. Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-200 in-lb (13-17 ft. lbs.)E. Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100 in-lb (6-8 ft. lbs.)F. Charge Cover Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-190 in-lb (13-16 ft. lbs.)G. End Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282-342 in-lb (23-29 ft. lbs.)H. Diagnostic Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-120 in-lb (7-10 ft. lbs.)I. Shock Valve Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160-200 in-lb (13-17 ft. lbs.)J. Fan, Nut, Hex Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250-270 in-lb (21-23 ft. lbs.)

B BH

G

I

F

GG

G

CE J

F

D

Rev. 12-04

Minor RepairMinor repairs may be performed, following the procedures in thissection.• Cleanliness is a primary means of assuring satisfactory life on

either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

• Protect all exposed sealing surfaces and open cavities from damage and foreign materials.

• It is recommended that all O-rings be replaced. Lightly lubri-cate all O-rings with clean petroleum jelly prior to assembly.

Plug Fitting TorquesIf any plugs or fi ttings are removed from the housing or end cap during servicing, they should be torqued as indicated in the torqu-ing chart. (See page 26)

Shaft SealsLip style seals are used on the input shaft and displacement con-trol shaft of these pumps. These seals can be replaced without major disassembly of the unit.1) To replace the pump input shaft seal, fi rst remove the retain-ing ring from the housing. Figure 12) Carefully pull the seal out of the housing bore. A "hook" type tool may be used to grasp the seal and pull it out. Figure 2Care must be taken not to damage the housing bore, shaft seal-ing surface or bearing. Once removed, the seal is NOT reusable.

NOTE: Once the pump input shaft seal is removed, the pump block spring may push the shaft partially out of the housing. Do not attempt to pull the shaft out of the housing. Internal parts could move out of alignment or fall into the transmission, requiring major disassembly of the unit.

Servicing and Repairing the BDP-10L Pump

3) Inspect the sealing are on the shaft for rust, wear or contami-nation. Polish the sealing area on the shaft if necessry.4) Lubricate the new seal with petroleum jelly.

Input shaft seal retaining ring removal. Figure 1

Input shaft seal removal.Figure 2

Input shaft seal, washer & retaining ring removed.

40

CAUTION: Do not allow the poppet to fall into the closed loop passages in the end cap.

Install input shaft seal.Figure 3

Shaft Seals (ctd)5) Slide the seal over the shaft and press it onto the housing bore. Be careful not to dam-age the seal. Figure 36) Install the seal retaining ring in the housing. Figure 4

Charge Check Valves1) Remove the check valve plug with a 1/4" internal hex wrench. Figure 52) Remove the valve spring and poppet from the pump end cap. Figure 6

3) Inspect the poppets and mating seats in the end cap for damage or foreign material.4) Lay the pump on its side and reinstall the poppet, spring and plug (O-ring) into the end cap. Be certain the poppet does not fall into the closed loop passage. Torque the plug to 15-20 ft. lbs. Turn the unit over and repeat for the other check valve.

Install input shaft seal retaining ring. Figure 4

Remove charge check valve. Figure 5

Remove valve spring & poppet. Figure 6

41Rev. 12-04

Rev. 12-04

Bypass Valve1) Unscrew the bypass valve from the end cap using a 5/8" wrench. Figure 72) Inspect the valve and mating seat in the end cap for damage or foreign material. It is rec-ommended that the O-ring and backup ring be replaced. Figure 83) Reinstall the bypass valve into the end cap. Torque to 7-10 ft. lbs.

Unscrew the bypass valve from end cap. Figure 7

Bypass valve components.Figure 8

42

NOTE: Make note of the correct orienta-tion prior to removing the charge pump cover.

Charge Pump1) The charge pump rotation is determined by the orientation of the charge pump cover on the end cap. There is an indentation stamped into the charge cover for the correct orienta-tion. Figure 9

Install gerotor assembly & charge relief valve ball &

spring. Figure 11

2) Using a 5 mm internal hex wrench, remove the two (2) screws holding the charge pump cover to the end cap. 3) Remove the charge pump cover and O-ring.4) Remove the charge pump gerotor assem-bly.5) Remove the charge relief valve spring and ball.6) Inspect the gerotor assembly, charge pump cover and end cap for abnormal wear, damage or foreign material. Inspect the charge relief valve seat in the end cap for damage or foreign material. Figure 107) Prior to installing the charge pump, apply a small quantity of petroleum jelly to the I.D., O.D. and side faces of the gerotor assembly.8) Install the charge relief valve ball and spring. Figure 119) Install the charge pump gerotor assembly. Figure 1110) Install the charge pump cover and O-ring. The charge relief valve spring must enter the recess in the cover.11) Install the charge pump cover screws. Torque each screw to 7-10 ft. lbs.

Charge pump components. Figure 10

Orientation of charge pump cover. Figure 9

43Rev. 12-04

Rev. 12-04

CAUTION: The pump cylinder block will stick to the surface of the end cap. Exercise caution to prevent damage to the end cap and cylinder block sealing surfaces.

Major RepairThe following procedures are for the complete disassembly and reassembly of the BDP-10L pump.• Again, cleanliness is a primary means of as-

suring satisfactory hydraulic unit life on either new or repaired units. Cleaning parts by using a clean solvent and air drying is usu-ally adequate. Protect all exposed sealing surfaces and open cavities from damage and foreign material.

• During reassembly of the pump all surfaces which have relative motion between two parts must be coated with a fi lm of clean oil or a lubricant such as petroleum jelly. This will assure that these surfaces will be lubri-cated during start-up.

• It is recommended that all O-rings and gas-kets be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.

Disassembly ProceduresPrior to performing major repairs on the pump, remove the external components as described in the "Minor Repair" section of this manual. (See page 29-32) These include the following: Plug/Fitting Shaft SealsCharge Check Valves Bypass ValveCharge Pump1) Lay the unit on its side. Using a 6 mm in-ternal hex wrench, remove the four (4) screws which retain the end cap to the pump housing. Figure 12

2) The internal springs should separate the end cap from the housing. Remove the end cap from the housing.

3) Remove the gasket and two (2) alignment pins from the housing. Figure 13

Remove end cap from housing. Figure 12

Remove gasket and two align-ment pins. Figure 13

44

Disassembly Procedures (ctd)4) Remove the pump cylinder block from the pump shaft. Figure 145) Remove the pump cylinder block spring and washer from the pump shaft. Figure 146) Remove the thrust bearing from the swash-plate.7) Remove the pump swashplate from the housing. Figure 148) Remove the slot guide block from the dis-placement control shaft.9) Remove the input shaft seal retaining ring. Figure 1510) Carefully pull the input shaft seal out of the housing bore. A hook may be used to pry the seal out. Care must be taken so as not to damage the housing bore, shaft sealing sur-face or bearing. Once removed, the seal is NOT reusable. Figure 1511) Remove the bearing spacer washer. Fig-ure 1512) Remove the pump shaft and bearing as-sembly from the housing. Figure 1513) Remove the outer bearing retaining ring and press the shaft out of the bearing. Figure 1614) Remove the displacement control shaft seal out of the housing. Care must be taken so as not to damage the housing bore.

Remove outer retaining ring & press the shaft out of the bear-

ing. Figure 16

Remove input shaft retaining ring, seal, washer & input shaft

from housing. Figure 15

Remove pump cylinder block, block spring, washer & swash-plate from housing. Figure 14

45Rev. 12-04

Rev. 12-04

Reconditionig and Replacement of Parts• After disassembly, all parts should be thoroughly cleaned in a suitable solvent. Replace ALL O-

rings, gaskets and shaft seals.• Inspect all parts for damage, nicks or unusual wear patterns. Replace all parts having unusual or

excessive wear or discoloration.• Inspect the seal surfaces, bearing surfaces and shaft splines. Polish the sealing areas on the

shafts if necessary. Replace any worn or damaged parts.• The pump shaft bushing is pressed into the end cap and should not be removed.• The running surfaces of the cylinder blocks MUST be fl at and free from scratches. If scratches or

wear are found on the running surface of the cylinder block or end cap, polish or replace the parts. When polishing these surfaces, up to 0.0004 inches may be removed. If this is not suffi cient to obtain a fl at surface, free of scratches, the part should be replaced.

46

CAUTION: Most parts have critical, high tolerance surfaces. Caution must be exercised to prevent damage to these surfaces during assembly. Protect ex-posed surfaces, openings and ports from damage and foreign material.

Assembly Procedures1) Clean and lightly oil parts prior to assem-bly of the variable pump. Be sure to torque all threaded parts to recommended torque specs. (See pages 26-28)

2) Install the displacement control shaft into the housing. Figure 17

CAUTION: Do not damage the shaft seal-ing surface.

NOTE: Do not stretch or deform the retaining ring.

3) Press the bearing onto the shaft. Install the new outer bearing retaining ring.

4) Install the pump shaft and bearing assem-bly into the housing. Figure 18

Install displacement control shaft. Figure 17

Remove input shaft retaining ring, seal, washer & input shaft

from housing. Figure 18

47Rev. 12-04

Rev. 12-04

Assembly Procedures (ctd.)5) Install the bearing spacer washer. Figure 196) Wrap the key end of the pump drive shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the new pump seal with petroleum jelly.7) Slide the seal over the shaft and press it in to the housing bore. Be careful not to damage the seal. Figure 208) Install the retaining ring. Figure 219) Install the slot guide block onto the dis-placement control shaft. Figure 22

Install the bearing spacer wash-er. Figure 19

Install input shaft seal. Figure 20

Install input shaft seal retaining ring. Figure 21

Install slot guide block. Figure 22

48

NOTE: When installing the thrust bear-ing assembly, be sure the thin thrust washer sits down on the swashplate.

Assembly Procedures (ctd.)10) Install the swashplate into the housing. The slot on the swashplate must engage the guide block on the displacement control shaft. Use a tool such as a screwdriver or magnet to hold the guide block in position while installing the swashplate. Figure 23

11) Install the thrust washer and pump cylinder block spring onto the pump shaft.12) Install the springs, piston washers and pis-tons into the cylinder block. The pistons must move freely in their bores. Figure 2413) With the pump swashplate in the "neutral" (0 angle) position and the pump housing laying on its side, install the pump cylinder block onto the pump shaft in the housing. Figure 2514) Check that the piston springs are centered in the cylinder block bores. If necessary, posi-tion them with a small screwdriver.

CAUTION: Do not damage the running surfaces of the cylinder blocks.

Swashplate components. Figure 23

Cylinder block components. Figure 24

Install pump cylinder block. Figure 25

49 Rev. 12-04

Rev. 12-04

CAUTION: Be certain all parts are prop-erly aligned. Do not force the end cap into position on the housing. Caution must be exercised to prevent damage to the end cap and cylinder block sealing surfaces.

Assembly Procedures (ctd.)15) Install the two (2) aligning pins, and install a new end cap gasket onto the housing.16) Lubricate the running surfaces of the end cap and cylinder blocks. Position the housing with the housing opening UP and install the end cap onto the housing.

17) When the end cap is properly installed, the internal springs will hold it away from the hous-ing approximately 3/8 inch.18) Install the four (4) screws which retain the end cap to the pump housing. Torque the screws evenly to 10-15 ft. lbs. Figure 2619) Rotate the shaft to assure correct assem-bly. When properly assembled, minimal torque should be required to turn the shaft.20) Wrap the end of the displacement control shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the new displacement control shaft seal with petroleum jelly. Slide the seal over the shaft and press it into the housing bore. Be careful not to dam-age the seal.21) Assemble the following componenets as described in the "Minor Repair" section of this manual. (See page 29-32) These include the following:Plug/Fitting Shaft SealsCharge Check Valves Bypass ValveCharge Pump

Install end cap. Figure 26

50

Purging the SystemThese purge procedures should be implemented anytime a hydrostatic system has been opened. Before starting, make sure the reservoir is at the proper oil level. The following procedures should be performed with the vehicle drive wheels off the ground, then repeat-ed under normal operating conditions.

WARNING: Certain procedures require the tractor's engine to be operated and the tractor to be raised off the ground. To prevent possible injury to the servicing tech-nician and/or bystanders, insure the tractor is properly secured.

1) With the bypass valve open and the engine running, slowly move the control arm for-ward and reverse (5 to 6 times). As air is purged from the unit, the oil level will drop.

2) With the bypass valve closed and the engine running, slowly move the control arm for-ward and reverse (5 to 6 times). Check the oil level and add oil as required after stop-ping the engine.

3) It may be necessary to repeat Steps 1 and 2 until all air is completely purged from the system. When the tractor moves forward and reverse at normal speed, purging is com-plete.

51Rev. 12-04

52Rev. 12-04

1 130050 Housing 2 130041 End Cap 3 130045 Dowel Pin 4 270080 Socket Head Screw 5 130038 Gasket 6 130023 Charge Cover 7 130061 Gerotor Assy 8 130021 O-Ring 9 270824 Socket Head Screw 10 Bypass Valve Assy 130017 Backup ring 130018 O-Ring 11 130179 Shaft Kit (Includes Items 12 and 16) 12 130081 Bearing 13 125364 Seal 14 130085 Spacer 15 130089 Seal Retaining Ring

16 130165 Input Bearing Retaining Ring 17 130151 Cylinder block Kit 18 130014 Block Spring 19 130218 Block Thrust Washer 20 130182 Swashplate 21 130013 Thrust Bearing 22 130036 Trunnion Arm 23 130065 Slot Guide 24A & B Check Valve Assy 130155 Poppet 130157 Poppet Spring 130031 O-Ring 130030 Check Plug 25 130025 Charge Relief 26 Cradle Bearing 27 125355 Trunnion Seal 130029 Trunnion Seal Retaining Ring 28 130176 Overhaul Seal Kit


53

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REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF INPUT SHAFT SEAL BDP-10A/16A/21L

Disassembly1) Remove retianing ring (22) from housing.2) Remove lip seal (20). Care must be taken to prevent damage to the housing bore, shaft sealing surface or bearing. Once removed the seal is NOT reusable.

Inspection1) With seal removed inspect the spacer (21), input shaft bearing (19) and housing (1) bore for damage, corrosion or wear.

Assembly1) Lubricate the new lip seal (20) with petro-leum jelly.2) Wrap the input shaft (18) with plastic wrap to prevent damage to the inner surface of the lip seal (20).3) Install spacer (21), slide seal (20) over shaft (18) so that lettering on the seal faces out.4) Press the lip seal (20) into the housing bore. Insure the lip seal (20), shaft (18) or housing (1) bore does not become damaged.5) Install the retaining ring (22) into the hous-ing (1) bore groove. Figure 1

Servicing and Repairing the BDP-10A/16A/21L PumpLip type seals (shaft seals) are used on the input shaft and directional control shaft of the BDP10A/16A/21L. These seals can be replaced without major disassembly of the unit.

Figure 1

54Rev. 12-04

REMOVAL, INSPECTION AND/OR REPLACE-MENT OF TRUNNION ARM (CONTROL ARM) SEAL BDP-10A/16A/21L

Disassembly1) Remove the retainer and lip seal (49) from the housing (1). Care must be taken to prevent damage to the housing trunnion bore, trunnion arm (37) and sealing surface. Once removed the retainer and lip seal is NOT reusable.

Inspection1) With the lip seal (49) removed, inspect the area for corrosion and wear. Inspect the trun-nion bore area sealing surface for damage or wear.

Assembly1) Lubricate the new lip seal (49) with petroleum jelly.2) Wrap the trunnion arm (37) with plastic wrap to prevent damage to the inner surface of the lip seal (49).3) Slide the lip seal (49) over the trunnion arm (37) so that the lettering on the seal (49) faces out.4) Press the lip seal (49) into the housing bore (1). Insure the seal (49), trunnion arm (37) and housing bore does not become damaged.5) Install the retainer from (49) over the trunnion arm (37) on top of the lip seal from (49). Press into the trunnion seal bore in the housing until it mates against the trunnion seal. Figure 2

Figure 2

55Rev. 12-04

56Rev. 12-04

REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF CHECK VALVES BDP-10A/ 16A

Disassembly

Perform disassembly, inspection and as-sembly on check valves one side at a time. Some units vary in "A" side to "B" side check confi guration.

1) Remove the check valve (42A) with 1/4" allen wrench.2) Remove the valve spring and poppet from the BDP end cap (2).

Inspection1) Inspect the poppets and mating seats in the end cap (2) for damage or foreign material.

Assembly1) Lay the BDP on its side, so the check plug port is horizontal.2) Insert the check plug, spring and poppet (42A) as one assembly into the check plug port. Torque plug to specifi cations found in "Tightening Torques" section. (See page 27) Figure 3

Figure 3

REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF CHECK VALVES BDP-21L

Disassembly1) Remove the check valve (42) with 1/4" allen wrench.2) Remove the valve spring and poppet from the BDP end cap (2).

Inspection1) Inspect the poppet and mating seats in the end cap (25) for damage or foreign material.

Assembly1) Lay the BDP on its side, so the check plug port is horizontal.2) Insert the check plug, spring and poppet (42) as one assembly into the check plug port. Torque plug to specifi cations found in "Tighten-ing Torques" section. (See page 28)

Repeat disassembly, inspection and assem-bly for the opposite port side. Figure 4

Figure 4

57 Rev. 12-04

REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF SYSTEM CHECK RELIEFS (SCR'S) BDP-10A/16A

Disassembly1) Remove the system check relief (SCR) (42B) with a 7/8" wrench.2) Remove the check relief spring and the check relief from the BDP end cap (2).

Inspection1) Inspect the check relief (42B) and mating seat in the end cap (2) for damage or foreign material.

Assembly1) Lay the BDP on its side, so the check plug port is horizontal.2) Insert the check plug, spring and poppet (42B) as one assembly into the check plug port. Torque plug to specifi cations found in "Tightening Torques" section. (See page 27) Figure 5

Figure 5

REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF BYPASS BDP-10A/ 16A

Disassembly1) Loosen the bypass valve (15) using a 5/8" wrench.2) Remove the bypass (15) from the BDP end cap (2).

Inspection1) Inspect the bypass O-rings an mating seats in the end cap (2) for damage or foreign mate-rial.2) If damaged or worn replace bypass (15).

Assembly1) Lay the BDP on its side, so the check plug port is horizontal.2) Insert the bypass (15) into the bypass port on the end cap (2). Torque plug to specifi ca-tions found in "Tightening Torques" section. (See page 27) Figure 6

Figure 6

58Rev. 12-04

REMOVAL, INSPECTION AND/OR RE-PLACEMENT OF BYPASS BDP-21L

Disassembly1) Loosen the bypass valve (50) using a 5/8" wrench.2) Remove the bypass (50) from the BDP end cap (25).

Inspection1) Inspect the bypass O-rings and mating seats in the end cap (25) for damage or for-eign material.2) If damaged or worn replace bypass (50).

Assembly1) Lay the BDP on its side, so the check plug port is horizontal.2) Insert the bypass (50) into the bypass port on the end cap (25). Torque plug to specifi ca-tions found in "Tightening Torques" section. (See page 28) Figure 7

Figure 7

59Rev. 12-04

REMOVAL, INSPECTION AND ASSEMBLY OF THE CHARGE PUMP BDP-10A/16A/21L

Disassembly1) Prior to removal of the charge cover, place a mark on the charge cover and end cap for realignment.2) Using a 1/2" wrench loosen the charge cov-er bolts from the BDP end cap (25) 16A-use 6 mm allen wrench. While holding the charge cover in place, remove the charge cover bolts (56).3) Remove the charge cover, O-ring, gerotor items (40), charge spring and charge ball (44).

Inspection1) Inspect the charge cover O-ring and run-ning surfaces for damage. Inspect the spring, check ball (44), and mating seat in the end cap (25) for damage or foreign material.2) If damaged or worn, replace O-ring and gerotor assembly (40), charge spring and charge ball (44) and end cap (25).

NOTE: If end cap (25) is to be removed, delay charge components reassembly.

Figure 8

Assembly1) Lay the BDP (input shaft down), so the end cap is horizontal. Place the charge ball in the end cap (25) charge pocket so it mates to the end cap (25) charge ball seat. Place the charge spring on top of the charge ball.2) Insert the inner gerotor over input shaft (1).3) Align the outer gerotor to fi t over the inner gero-tor.4) Insert the O-ring into the charge cover.

5) Position the charge cover and O-ring with the aligning mark on the end cap (25). Place the charge cover and O-ring as one piece over the charge spring and gerotor assembly. Insure the spring fi ts into the charge cover spring retaining groove.6) Align and insert the cap screws (56) into the end cap (25). Torque bolts to specifi ca-tions found in "Tightening Torques" section. (See page 28) Figure 8

60

REMOVAL, INSPECTION AND ASSEMBLY OF THE END CAP AND VALVE PLATE BDP-10A/16A/21L

Disassembly1) Using any combination of two, 9/16" wrenches or 9/16" socket and rachet drive, loosen the end cap bolts (58) evenly. 10A-use 10 mm, 16A-use 1/2".2) Keeping the end cap (25) held in place remove the four end cap bolts (58).3) Slowly remove the end cap (25).4) Remove the valve plate (29).5) Remove housing alignment pins (26).6) Remove housing gasket (28).

Inspection1) Inspect the end cap (25) body for damage, nicks or unusual wear patterns. Replace if necessary.2) Inspect the bronze side of the valve plate (29). The running surface may show evi-dence of minor abrasive rings. This is normal. Grooving in the plate, or material transfer that is evident when the surface is checked by

Figure 9

dragging a fi ngernail across it, would be cause for replacement of the valve plate.3) Inspect and replace alignment pins (26) if bent or distorted.4) Replace the housing O-ring (28) with a new O-ring before reassembly.

Assembly1) Install housing O-ring (28) into housing O-ring seat in housing (15).2) Install alignment pins (26) into housing (15).3) Install valve plate (29) with bronze side down (21L Only) on top of cylinder block. On 10A & 16A install valve plate with lettering facing up (i.e. "CL" or "UP").4) Install end cap (25). Before installing the four end cap bolts (58), push down on end cap (25) verifying alignment and insuring that the cylinder block pistons spring back and forth. Install end cap bolts. Torque bolts to specifi cations found in "Tightening Torques" section. (See page 28)Figure 9

Rev. 12-04

Rev. 12-0461

REMOVAL, INSPECTION AND ASSEM-BLY OF THE CYLINDER BLOCK BDP-10A/16A/21L

Disassembly1) Tilt the BDP on its side, drain remaining oil. Lift out the cylinder block assembly (38).2) Remove the pistons, springs and piston seats.

Inspection1) Inspect the running surface of the cylinder block and piston ends for damage, nicks or un-usual wear patterns. The running surface may show evidence of minor abrasion. This will be normal wear. If grooved or smeared, replace with a new cylinder block assembly.2) Inspect the piston springs for distortion or breakage. If necessary, replace with new cylin-der block kit.3) Inspect the piston seats. Residual oil may cause these to remain stuck to the inside of the pistons.

Assembly1) Install piston seats into the end of the pis-tons.2) Install springs into the pistons.3) Install one at a time; pistons, springs and seats as one assembly into the cylinder block.4) With the BDP housing tilted on its side, install the cylinder block assembly (38) with pistons contacting the thrust bearing. Figure 10

Figure 10

NOTE: To check piston placement is correct, push downward on the cylin-der block assembly (38). If it results with a spring action, the block has been assembled correctly without pistons slipping out. If this cannot be accom-plished, place a rubber band around the cylinder block pistons to hold them in position during installation. Then, after installation, cut the rubber band and re-move it. Check for piston spring action.

62

REMOVAL, INSPECTION AND ASSEMBLY OF BLOCKSPRING, THRUST WASHER AND THRUST BEARING BDP-10A

Disassembly1) Remove the block spring (29).2) Remove the thrust washer (30).3) Remove the thrust bearing and race (34).

Inspection1) Inspect and replace the block spring (29) and thrust washer (30) if they are distorted or broken.2) Inspect the running surface of the bearing race for damage, nicks or unusual wear pat-terns. The running surface may show evi-dence of minor abrasion. This will be normal wear. Inspect the bearings for free movement. Inspect the bearing cage for distortion or dam-age. Replace if necessary.

Assembly1) Install thrust bearing and race assembly (34).

NOTE: The difference in race thickness: the thin race seats into the swashplate (32). The thicker race will be installed toward the piston noses.

2) Install thrust washer (30).3) Install block spring (29). Figure 11

Figure 11

REMOVAL, INSPECTION AND ASSEMBLY OF THRUST BEARING BDP-21L/ 16A

Disassembly1) Remove the thrust bearing and race (17).

Inspection1) Inspect the running surface of the bearing race for damage (17), nicks or unusual wear patterns. The running surface may show evi-dence of minor abrasion. This will be normal wear. Inspect the bearings for free movement. Inspect the bearing cage for distortion or dam-age. Replace if necessary.

Assembly1) Install bearing and race assembly (17).Figure 12

NOTE: The difference in race thickness: the thin race seats into the swashplate. The thicker race will be installed toward the piston noses.

Figure 12

Rev. 12-04

Rev. 12-0463

REMOVAL, INSPECTION OF SWASHPLATE, INSPECTION OF CRADLE BEARINGS BDP-10A/16A/21L

Disassembly1) Remove the swashplate (31).

Inspection1) Inspect the running surface of the bearing pocket for damage (31), nicks or unusual wear patterns. The running surface may show evi-dence of minor abrasion. This will be normal wear. Inspect the cradle bearing side of the swashplate (31) for damage. Replace if neces-sary.2) Inspect the cradle bearings attached to the inside of housing (15) for normal wear patterns, placement and insure they are staked in place. If damaged, replace housing (15).

NOTE: The cradel bearings will have discoloration due to normal wear. This under normal circumstances will not warrant replacement.

Figure 13

Assembly1) Install swashplate (31) by holding trunnion arm's (13) slot guide (14) with the aide of a fl at tip screwdriver. Use the screwdriver to hold the slot guide (14) in place while positioning the swashplate (31) onto the cradle bearing in the housing (15).2) Rotate trunnion arm (13) to assure swash-plate pivoting action. Figure 13

64

REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT BDP-10A

Disassembly1) Remove the retaining ring (22).2) Remove the lip seal (20).3) Remove the spacer (21).4) Remove the shaft assembly (18) from the pump.

Inspection1) Inspect the input shaft (18) for worn aplines, surface damage or keyway damage. Replace shaft assembly if necessary.2) Inspect the bearing (19) for evidence of scoring, corrosion or damage. Replace shaft assembly if necessary.3) Inspect and replace the spacer (21) if it is bent or broken.4) Inspect and replace the retaining ring (22) if it is bent or broken.

Figure 14

1) Install input shaft assembly (18) into the housing (1) bore. Light tapping with a rubber mallet may be necessary on the input shaft (18) once the bearing is aligned with the hous-ing (1) bore. Rotate the input shaft (18) to insure free movement.2) Install spacer (21).3) Install new lip seal (20).4) Install retaining ring (22). Figure 14

NOTE: If trunnion arm is to be removed, delay reassembly of input shaft assem-bly.

NOTE: Upon removal, it is recommended that all seals, O-rings and gaskets be re-placed. During installation, lightly lubri-cat e all seals, O-rings and gaskets with clean petroleum jelly prior to assembly. Also, protect the inner diameter of seals by covering the shaft with plastic wrap.

Assembly

NOTE: Replace the input shaft seal (20) after removal.

Rev. 12-04

Rev. 12-0465

REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT BDP-16A/21L

Disassembly1) Remove the retaining ring (3).2) Remove the lip seal (6).3) Remove the spacer (4).4) Remove the shaft assembly (1) from the pump.

Inspection1) Inspect the input shaft (1) for worn splines, damage or keyway damage. Replace shaft as-sembly if necessary.2) Inspect the bearing (5) for evidence of scoring, corrosion or damage. Replace shaft assembly if necessary.3) Inspect and replace the spacer (4) if it is bent or broken.4) Inspect and replace the retaining ring (3) if it is bent or broken.

Figure 15

1) Install shaft assembly (1) into the housing (15) bore. Light tapping with a rubber mallet may be necessary on the input shaft (1) once the bearing is aligned with the housing (15) bore. Rotate the input shaft (1) to insure free movement.2) Install spacer (4).3) Install the lip seal (6).4) Install the retaining ring (3). Figure 15

NOTE: If trunnion arm is to be removed, delay reassembly of input shaft assem-bly.

NOTE: Upon removal, it is recommended that all seals, O-rings and gaskets be re-placed. During installation, lightly lubri-cate all seals, O-rings and gaskets with clean petroleum jelly prior to assembly. Also, protect the inner diameter of seals by covering the shaft with plastic wrap.

5) Inspect and replace the thrust spring (20) and thrust washer (19) if they are distorted or broken.

Assembly

NOTE: Replace the input shaft seal (6) after removal.

66Rev. 12-04

REMOVAL, INSPECTION TRUNNION ARM BDP-10A/16A/21L

Disassembly1) Remove trunnion seal retainer and seal (49).2) Remove slot guide (38).3) Remove trunnion arm (37).

Inspection1) Inspect the trunnion arm (37) for wear or damage. Replace trunnion if necessary.

NOTE: Replace the trunnion shaft seal and retainer (49) after removal.

Assembly1) Install the trunnion arm (37) into the hous-ing (1) bore. Rotate the trunnion arm to insure free movement.2) Install new seal and retainer from seal kit.Figure 16

NOTE: Upon removal, it is recommend-ed that all seals, O-rings and gaskets be replaced. During installation, lightly lubricate all seals, O-rings and gaskets with clean petroleum jelly prior to as-sembly. Also protect the inner diam-eter of seals by covering the shaft with plastic wrap.

Figure 16

BDP-10A

9

67

8

30

1211

4

102

27

26 29

5

32

3

21

28

1

1314

1517

16

2425

22

2320

19

18

67 Rev. 4-11

31 Seal Kit

1 130052 Housing Kit 2 130042 End Cap Kit w/ thru shaft and SCR 130043 End Cap Kit w/ thru shaft & shock valve 130039 End Cap Kit without thru shaft 3 130046 Dowel Pin 4 271075 Housing Bolt 5 130181 Molded Seal Ring 6 130022 Charge Cover (10A with Fans) 130023 Charge Cover (10A without Fans) 7 130062 Gerotor Set (10A with Fans) 130061 Gerotor Set (10A without Fans) 8 130020 Charge Cover Seal Ring (10A with Fans) 130021 Charge Cover Seal Ring (10A without Fans) 9 270825 Charge Cover Screw-Socket head without thru shaft 270078 Charge Cover Screw with thru shaft 243205 Charge Cover Screw-Hex Head 10 Bypass Valve 11 130017 Backup Ring 12 130018 O-Ring 13 130174 Shaft and Bearing Kit w/ thru shaft 130173 Shaft and Bearing Kit w/o thru shaft 14 130078 Ball Bearing 15 125365 Input Seal

16 130087 Spacer 17 130090 Retaining Ring 18 130151 Block Kit 19 130014 Block Spring 20 130218 Block Thrust Washer 21 130212 Valve Plate 22 130182 Swashplate 23 130013 Thrust Bearing 24 130036 Trunnion Arm 25 130065 Slot Guide 26A 130030 Check Plug 130031 Check Plug O-Ring 130155 Poppet 130157 Poppet Srping 26B System Check Relief 126535 SCR O-Ring 130160 Shock Valve 130031 O-Ring 27 130019 Charge Relief Kit 28 125355 Trunnion Seal Kit 29 103739 Straight Thread Plug 30 125164 Fan Shaft Seal 31 130175 Seal Kit 32 130160 Shock Valve Kit

Item Order Description Item Order DescriptionNo. No. No. No.

68Rev. 7-12

1 130052 Housing Kit 2 130037 End Cap Kit (No Valve Plate) 3 130046 Dowel Pin 4 271075 Housing Bolt 5 130181 Molded Seal Ring 6 130022 Charge Cover 7 130062 Gerotor Set 8 130020 Charge Cover Seal Ring 9 243205 Charge Cover Screw-Hex Head 10 Bypass Valve 11 130017 Backup Ring 12 130018 O-Ring 13 130174 Shaft and Bearing Kit w/ thru shaft 14 130078 Ball Bearing 15 125365 Input Seal 16 130087 Spacer 17 130090 Retaining Ring 18 130153 Block Kit 19 130014 Block Spring

20 130218 Block Thrust Washer 21 130182 Swashplate 22 130013 Thrust Bearing 23 130036 Trunnion Arm 24 130065 Slot Guide 25A 130030 Check Plug 130031 Check Plug O-Ring 130155 Poppet 130157 Poppet Srping 25B System Check Relief 126535 SCR O-Ring 130160 Shock Valve 130031 O-Ring 26 130019 Charge Relief Kit 27 125355 Trunnion Seal Kit 28 103739 Straight Thread Plug 29 125164 Fan Shaft Seal 30 130175 Seal Kit 31 130160 Shock Valve Kit


22

23

18

2019

17

1112

1314

15

16

31

26

7

21

24

25

27

29

10

5

2

3

1

4

6

9

8

28

30 Seal Kit

PK-12

69 Rev. 7-12

1 130088 Retaining Ring 2 125363 Input Seal 3 130086 Spacer 4 130170 Wire Retaining Ring 5 130080 Input Bearing 6 130220 Block Thrust Washer 7 130015 Block Spring 8 130178 Shaft Kit 9 125357 Trunnion Seal Kit 10 130054 Housing Kit 11 130046 Locating Pin 12 130184 Molded Seal Ring 13 103739 SAE Plug 14 130160 Shock Valve 15 130030 Check Plug 16 130031 Check Plug O-Ring 17 130157 Poppet Spring 18 130155 Poppet 19 130027 Charge Relief Kit 20 130020 Charge Cover Seal Ring 21 130060 Gerotor Set 22 130022 Charge Cover

23 125165 Fan Shaft Seal 24 270078 Socket Head Cap Screw 25 271080 Flanged Head Hex Screw 26 130018 O-Ring 27 130017 Back up Ring 28 Bypass Valve (with O-Rings) 29 130214 Valve Plate (This plate has been omitted on tractors with serial number 6100000 & above which have pumps with serial number 0216P00000 & above) 30 130152 Block Kit 31 130008 Thrust Bearing 32 Swashplate 33 130065 Guide Block 34 130035 Trunnion Arm 35 130044 End Cap * 130048 End Cap (Use only on tractors with serial number 6100000 & above which have pumps serial number 0216P00000 & above) 36 130186 Seal Kit


70Rev. 7-12

222423

20

2826

29

15

25A

910

1912

21

2725B

17

16

1816

87

11

30

114 13

22

56

3

31 SEAL KIT

4

1 130178 Tapered Shaft S/A (Includes Items 2, 5, 13, 14) 2 130170 Wire Retaining Ring 3 130088 Seal Retaining Ring 4 130086 Spacer 5 130080 Input Bearing 6 125363 Input Seal 7 130028 Seal Retaining Ring 8 125360 Trunnion Seal 9 130035 Trunnion Arm 10 130065 Slot Guide 11 130056 Housing 12 130012 Thrust Bearing 13 130220 Block Thrust Washer 14 130015 Block Spring 15 130040 End Cap * 130047 End Cap (Use only on tractors with serial number 6100000 & above which have pumps serial number 0216P00000 & above) 16 130046 Dowel Pin 17 130180 Square Cut Seal Ring

18 130210 Valve Plate (This plate has been omitted on tractors with serial number 6100000 & above which have pumps with serial number 0216P00000 & above) 19 Swashplate 20 125165 Seal 21 130150 Cylinder Block Kit 22 130020 Seal Ring 23 130022 Charge Cover 24 130060 Gerotor Assy 25A & B Check Valve Assy 130155 Poppet 130157 Poppet Spring 130031 O-Ring 130030 Check Plug 26 130027 Charge Relief Kit 27 Bypass Valve Assy 130018 O-Ring 130017 Back-up Ring 28 243205 Hex Screw 29 Flange Head Hex Screw 30 130075 Hex Flange Nut 31 130177 Seal Kit


Rev. 09-1671


1 130455 HOUSING ASSEMBLY 2 130413 THRUST BEARING 3 130457 SEAL RING 4 125365 SEAL - INPUT 5 130423 CHARGE COVER (NO FAN) 130422 CHARGE COVER (FAN) 6 130425 GEROTOR SET 7 130415 SWASHBLOCK 8 130417 CONTROL BLOCK 9 130405 RETAINING RING 10 130473 SPRING 11 130419 TRUNNION ARM 125359 TRUNNION SEAL 130402 RETAINING RING 12 130459 DOWEL PIN 13 130426 CHARGE RELIEF KIT 14 130448 BYPASS VALVE 130517 BYPASS VALVE BACKUP RING 130518 BYPASS VALVE O-RING 15 130421 SEAL RING - CHARGE COVER (NO FAN) 130420 SEAL RING - CHARGE COVER (w/FAN)

16 000000 17 130407 WASHER 18 000000 19 000000 20 125162 SEAL - THRU SHAFT 21 130479 THRUST WASHER 22 130430 FAN HUB 23 SEE DRIVE ASSEMBLY PAGE 24 130466 SHAFT & BARREL ASSEMBLY 130467 SHAFT & BARREL ASSEMBLY - THRU SHAFT 25 130453 PORT PLATE 26 130437 END BLOCK ASSEMBLY - LEFT 130440 END BLOCK ASSEMBLY - RIGHT 27 130475 SHAFT ASSEMBLY (NO FAN) 130477 THRU SHAFT ASSEMBLY (FAN) 130482 BEARING - INPUT 130483 BEARING - RETAIN RING 28 130432 WASHER - FAN RETAIN ER 29 130443 CHECK VALVE ASSEMBLY 130447 O-RING 30 253461 NUT - INSERT - NYLON 31 130401 SEAL KIT

94

17

27

11

3

119

7 8

12

21

12

24

25

14

2

10

29

29

16

16

13

1516 18

520

26

6

H1-10 Assembly

31 - Seal Kit

23

2830

22

72


1 130454 HOUSING ASSEMBLY 2 130412 THRUST BEARING 3 130456 SEAL RING 4 125370 SEAL - INPUT 5 130447 O-RING 6 130422 CHARGE COVER 7 130424 GEROTOR SET 8 130414 SWASHBLOCK 9 130416 CONTROL BLOCK 10 130404 RETAINING RING 11 130472 CENTER SPRING 12 130418 TRUNNION ARM 125358 SEAL - TRUNNION 130402 RETAINING RING 13 130458 DOWEL PIN 14 130427 CHARGE RELIEF KIT 15 130448 BYPASS VALVE 130517 BYPASS VALVE BACKUP RING 130518 BYPASS VALVE O-RING 16 130420 SEAL RING - CHARGE COVER 17 000000 18 130406 WASHER

19 271023 HEX BOLT 20 000000 21 125162 SEAL - THRU SHAFT 22 130430 FAN - HUB 23 130432 WASHER - FAN RETAINER 24 130450 PISTON & BARREL ASSEMBLY 25 130451 PORT PLATE 26 130438 END BLOCK - LEFT 130439 END BLOCK - RIGHT 27 130474 SHAFT ASSEMBLY 130480 INPUT BEARING 130481 BEARING RETAINING RING 28 253461 NUT - INSERT - NYLON 29 130445 SHOCK VALVE ASSEMBLY 130447 O-RING 30 130444 CHECK VALVE ASSEMBLY 130447 O-RING 31 SEE DRIVE ASSEMBLY PAGE 32 130400 SEAL KIT

104

18

27

5

12

3

1

208

9

13

24

25

152

11

29

30

17

17

14

1617

26

7

H1A-12 Assembly

32 - Seal Kit

19

6

31

23

2122

28

Rev. 01-12

Rev. 09-1673


1 130460 HOUSING ASSEMBLY 2 130413 THRUST BEARING 3 130457 SEAL RING 4 125365 SEAL - INPUT 5 130447 O-RING 6 130410 CHARGE COVER (NO FAN) 130422 CHARGE COVER (FAN) 7 130428 GEROTOR SET 8 130415 SWASHBLOCK 9 130417 CONTROL BLOCK 10 130405 RETAINING RING 11 130473 SPRING 12 130419 TRUNNION ARM 125359 SEAL - TRUNNION 130402 RETAINING RING 13 130459 DOWEL PIN 14 130426 CHARGE RELIEF KIT 15 130448 BYPASS VALVE 130517 BYPASS VALVE BACKUP RING 130518 BYPASS VALVE O-RING 16 130420 SEAL RING - CHARGE COVER 17 000000 18 130407 WASHER

19 271023 HEX BOLT 20 000000 21 125162 SEAL - THRU SHAFT 22 130430 FAN - HUB 23 130432 WASHER - FAN RETAINER 24 130467 SHAFT & BARREL ASSEMBLY - THRU SHAFT 130466 SHAFT & BARREL ASSEMBLY 25 130453 PORT PLATE 26 130441 END BLOCK - LEFT 130442 END BLOCK - RIGHT 27 130476 SHAFT ASSEMBLY (NO FAN) 130477 THRU SHAFT ASSEMBLY (FAN) 28 253461 NUT - INSERT - NYLON 29 *000000 CHECK VALVE ASSEMBLY 126540 O-RING 30 SEE DRIVE ASSEMBLY PAGE 31 130479 THRUST WASHER 32 130401 SEAL KIT

* VALVE NOT AVAILABLE

104

18

27

5

12

3

120

8 9

13

31

13

24

2515

2

11

29

29

17

1714

1617

3019

6 2122

2328

26

7

H3-10 Assembly

32 - Seal Kit

Rev. 10-12 74


1 130454 HOUSING ASSEMBLY 2 130412 THRUST BEARING 3 130456 SEAL RING 4 125370 SEAL - INPUT 5 130447 O-RING 6 130422 CHARGE COVER 7 130424 GEROTOR SET 8 130414 SWASHBLOCK 9 130416 CONTROL BLOCK 10 130404 RETAINING RING 11 130472 CENTER SPRING 12 130418 TRUNNION ARM 125358 SEAL - TRUNNION 130402 RETAINING RING 13 130458 DOWEL PIN 14 130427 CHARGE RELIEF KIT 15 130448 BYPASS VALVE 130517 BYPASS VALVE BACKUP RING 130518 BYPASS VALVE O-RING 16 130420 SEAL RING - CHARGE COVER 17 000000 18 130406 WASHER

19 271023 HEX BOLT 20 000000 21 125162 SEAL - THRU SHAFT 22 130430 FAN - HUB 23 130432 WASHER - FAN RETAINER 24 130450 PISTON & BARREL ASSEMBLY 25 130465 PORT PLATE 26 130462 END BLOCK - LEFT 130463 END BLOCK - RIGHT 27 130474 SHAFT ASSEMBLY 130480 INPUT BEARING 130481 BEARING RETAINING RING 28 253461 NUT - INSERT - NYLON 29 *000000 126540 O-RING 30 130431 FAN - HYDRO 31 130400 SEAL KIT

* VALVE NOT AVAILABLE

104

18

27

5

12

3

1

208

9

13

13

24

2515

2

11

29

29

17

17

14

1617

19

6

30

26

7

H4-12 Assembly23

2122

28

31 - Seal Kit

G1 & G2 TOOL KITPart Number 609012

This kit provides tools for removing sheves and axle hubs on G1 and G2 units. It contains: (A) crowfoot wrenches (used when taking the spply tubes off the pumps and wheel motors on the 721D2, 725G2 and 928D2 tractors), a (B) hub puller (used to remove the axle hub on the G1 and G2 wheel motors) and a (C) sheave puller (used to remove the drive sheaves on the G1 and G2 pumps). Also included in the kit are four each of the following cap fi ttings: part number 360520 (used on 220, 225 and 321D models), part number 360522 (used on 325 models) and part number 360524 (used on 721D2, 725G2 and 928D2 models).

Item Order DescriptionNo. No.

A 098800 Crowfoot Wrench 098805 Crowfoot WrenchB 609010 Hub PullerC 609011 Sheave Puller

A

B

C

HUB REMOVAL

Raise and block drive tire off the ground to pre-vent accidental tractor movement. Remove the fi ve lug bolts from drive hub.

Lug Bolts

Remove axle nut. Disconnect brake linkage and remove brake caliper mount.

Brake Caliper

Axle Nut

75 Rev. 12-04

Tap the two puller holes with 1/2"-20 tap to clear the threads of paint and dirt.

SHEAVE REMOVAL FROM DRIVE PUMP

On mid-mount models, remove belt shield from rear of the machine.

Remove pump belt and nut from pump sheave.

Install puller as shown with light oil on the bolt threads. Tighten the bolts evenly so they do not bind up in the the puller. Do not use a jaw type or T-bar puller with a center point screw as you may damage the axle.

IMPORTANTWhen reinstalling the hub make sure the woodruff key is in place in the axle. Torque axle nut to 300 ft. lbs. It may be necessary to set the parking brake and install two wheel lugs in hub. Place a long bar between lug bolts to prevent hub from turning when torquing axle nut.When reinstalling the wheel, torque the lug bolts to 85 ft. lbs.

Shaft Nut

Belt

76Rev. 12-04

Rev. 12-04

Tap the two puller holes with a 1/4"-20 tap to clear the thread of paint and dirt.

IMPORTANTWhen reinstalling the pump sheave, make sure the woodruff key is in place.

Install puller as shown with light oil on the bolt threads. Tighten the bolts evenly so they do not bind up in the puller. Do not use a jaw type or T-bar puller with a center point screw as you may damage the shaft and/ or sheave.

Retaining Nut Torque Specifi cations:G2 (16A & 21L) .437 nut 45-54 ft. lbs.G1 (10L) .375 nut 27-37 ft. lbs.G1 (10A) 6 mm bolt 10-11 ft. lbs.

77

��

��

��

HYDRO PUMP FLOW TEST KITPart Number 609009

Used on models with G2, H2 & T Drives

78

TESTING PROCEDURE: 1. Raise and block drive tires off ground to

prevent accidental tractor movement. 2. Pull PTO fuse to prevent accidental engage-

ment of deck blades. 3. Remove any shielding to gain access to the

pumps. Shielding that has been removed must be put back into its original posi-tion when fi nished testing.

4. Clean the area around the pump to prevent contaminants from entering the system.

5. On the out front mowers, loosen the fi ttings from the wheel motor a couple of turns but do not remove. Remove both supply tubes from the pump being tested using a 1 1/4 fl are crowfoot (P/N 098800). If adapter comes off with tube, use a 1 1/8 straight crowfoot (P/N 098805) to hold the adapt-er. Once you have tube fi ttings loose from adapter fi ttings, swing the tubes to the side. (The 90 degree fi tting hose P/N 424340 and coupling fi tting P/N 360067 are used when testing the left pump on a 200 se-ries with a 10L pump).

6. Connect the lines from the fl ow meter to the fi ttings on the pump. Notice there are two sets of adapter fi ttings with this kit. (A)

(P/N 360007) is used on the out front mowers and (P/N 360066) is used on the 325. It does not matter which way the hoses are attached to the pump. This is a bi-direc-tional fl ow meter that will measure GPM in either direction.

7. Open the restriction valve on the test meter (B) all the way, start engine and run at full speed with the steering lever fully stroked. Do this until fi ttings on fl ow meter are hot to the touch.

8. With the steering lever at full stroke, ad-just throttle until 10GPM (C) is achieved when testing on a unit with 21L pumps. On units with 10L, 10A, 16A, H1-10, H1A-12,

T and T6 pumps, the steering and throttle levers must be fully stroked. Depending which direction you’re stroking the steering lever, one of the pressure gauges (D) shows very little pressure. This is normal. Record the GPM.

Rev. 7-08

Rev. 7-0879

9. Adjust the restriction valve in until one of the gauges reaches 1100 PSI and record your GPM. DO NOT LET THE UNIT RUN UNDER PRESSURE FOR MORE THAN A COUPLE OF MINUTES AS THE FLUID WILL BEGIN TO GET VERY HOT!!

10. Open the restriction valve, move steering lever back to neutral, idle engine down and shut off.

11. Determine the difference between the two fl ow readings. This difference is the GPM drop of the pump.

Always wear eye protection when work-ing with high-pressure oil lines.

Do not make contact with any oil lines or fi ttings when under high pressure. Even a small pinhole leak could inject hot oil under the skin and cause serious illness.

Acceptable Flow Drop

Pump Model Flow Drop

21L Less than 3 GPM*

10A/10L/H1-10/H1A-12/T Less than 2 GPM*

* If Flow Drop is greater than these specifi-

cations the pump will need to be serviced or

replaced. If you need additional assistance,

contact Grasshopper technical service.

16A/T6 Less than 2.5 GPM*

CAUTION

WARNING

80Rev. 8-13

G1/G2/H1/H2 TRANSMISSION APPLICATION GUIDE

PUMPS - MID MOUNTS

Tractor Model Serial Numbers Pump Left Right

120, 120K, 124/48 5818509 & below H1-10 391432 391433120K, 124/48 5818510 thru 6299999 H3-10 391438 391439

124/41 5817476 & below H1-10 391432 391433124/41 5817477 thru 6299999 H3-10 391438 391439124/52 5818557 & below H1-10 391432 391437124/52 5818558 thru 6299999 H3-10 391438 391440

218 All 10A 391456 391457220 5299999 & below 10L 391455 391455220 5310174 thru 5310443 10A 391448 391449220 5310444 thru 6059999 10A 391456 391457220 6060000 thru 6299999 H4-12 391446 391447220 6300000 & above PK-12 391464 391465223 6059999 & below 10A w/Fans 391460 391461223 6060000 thru 6299999 H4-12 391446 391447223 6300000 & above PK-12 391464 391465225 5113810 & below 10L 391455 391455225 5113811 thru 5499999 10A w/Fans 391460 391461

226V All H3-10 391442 391443227 6059999 & below 10A w/Fans 391460 391461227 6060000 thru 6299999 H4-12 391446 391447227 6300000 thru 6499999 PK-12 391464 391465

321D 5299999 & below 10A w/Fans 391460 391461321D 5300000 & above 16A 391462 391463322D All 16A 391462 391463325 5299999 & below 21L 391452 391453325 5300000 & above 16A 391462 391463

325D All 16A 391462 391463325A, 327A All 16A 391462 391463

327KWAll 16A 391462 391463

329, 329B All 16A 391462 391463335 All 16A 391462 391463

428D, 430D, 432 All 21L 391452 391453Rebuilt Part Numbers 10A w/Fans 604862 604863Rebuilt Part Numbers 16A 604866 604867Rebuilt Part Numbers 21L 604868 604869

225 6400000 & above PK-12 391464 391465

327KEFIAll 16A 391462 391463

81Rev. 10-10

PUMPS - FRONT MOUNTS

Tractor Serial Pump

Model Numbers Left Right

718K H2

All H1A-12 391434 391435

721G2

All 16A 391462 391463

721D2

5299999 & below 21L 391452 391453

721D2

5300000 & above 16A 391462 391463

721D H2

H1A-12 391434 391435

722D2

All 16A 391462 391463

723K H2

All H1A-12 391434 391435

725K2, 727K

2All 16A 391462 391463

725A, 727A All 16A 391462 391463

727KW All 16A 391462 391463

725G2

All 21L 391452 391453

729G2

All 16A 391462 391463

928D2, 930D

2, 932 All 21L 391452 391453

Rebuilt Part Numbers 10A w/Fans 604862 604863

Rebuilt Part Numbers 16A 604866 604867

Rebuilt Part Numbers 21L 604868 604869

82

MOTORS

Rev. 08-10

Tractor Serial

Model Numbers Left/Right

120, 120K, 124 All 603612

218 All 603603

220, 225 5299999 & below 603595

220, 225 5300000 & above 603603

223 All 603603

226V/52 All 603617

226V/61 All 603603

227 All 603603

321D 5299999 & below 603595

321D 5300000 & above 603602

322D All 603602

325 5299999 & below 603610

325 5300000 & above 603602

325D All 603602

325A, 327A All 603602

327KW All 603602

329, 329B All 603602

335 All 603602

428D, 432 5299999 & below 603610

428D, 430D, 432 5300000 & above 603604

718KH2, 723KH2All 603611

721G2All 603602

721D2491918 & below 603597

721D2491919 to 5299999 603596

721D25300000 & above 603602

721D H2All 603611

722D2All 603602

725K2, 727K2All 603602

725A, 727A All 603602

725G2491918 & below 603597

725G2491919 to 5299999 603596

725G25300000 & above 603604

727KW All 603602

729G2All 603602

928D2 491918 & below 603599

928D2 491919 to 5299999 603598

928D2, 930D2 5300000 & above 603604

932 491918 & below 603599

932 491919 to 5299999 603598

932 5300000 & above 603604

TRANSMISSION MAINTENANCE

83Rev. 03-16

CoolTemp Hydro-MaxTM Extended-Life Hydrostatic Fluid used in all systems listed above:345044: 1 quart345046: 2 gallon

*Once fluid has been changed to CoolTemp Hydro-MaxTM Extended-Life Hydrostatic Fluid, fluid & filterchange intervals become 1000 hours.

Transmission Maintenance Specificationsfor Pump & Wheel Motor Drive Tractors

Tractor Model Fluid ChangeInterval

Flilter ChangeInterval

Refill Capacitywith Fluid & Filter Change

(approximate)MID MOUNTS

FRONT MOUNTS

100 Series w/SN 6299999 & below, 225V, 226V 500 hours 500 hours 1.5 qts (1.42 l)100 Series w/SN 6300000 & above 300 hours 300 hours 2.0 qts (1.89 l)200 (except 225V & 226V), 300, 400 Series 1000 hours 1000 hours 5.5 qts (5.20 l)

700 Series D2, G2, K2, A & KW w/SN 5517203 & above 1000 hours 1000 hours 4.5 qts (4.26 l)700 Series D2, G2, K2, A & KW w/ SN 5517202 & below 1000 hours 1000 hours 7.0 qts (6.62 l)900 Series D2 & G2 w/SN 5517203 & above 1000 hours 1000 hours 5.0 qts (5.20 l)900 Series D2 & G2 w/SN 5517202 & below 1000 hours 1000 hours 7.0 qts (6.62 l)H2 Series without Hydraulic Lift 1000 hours 1000 hours 2.0 qts (1.89 l)H2 Series with Hydraulic Lift 1000 hours 1000 hours 4.0 qts (3.79 l)T Series w/SN 5999999 & below* 500 hours 500 hours 2.2 qts (2.08 l)T Series w/SN 6000000 & above 1000 hours 1000 hours 2.2 qts (2.08 l)

G1-G2-H2 Transmission Manual - The Grasshopper...

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