Kohler K161, Owner'S Manual

Page 1: ...ade from precision formulated castiron and because the cast iron cylinders can be rebored these engines can last even longer n Kohler engines are easy to service all routine service parts points condenser spark plug air filter carburetor are easily and quickly accessible 0 Every Kohler engine is backed by a worldwide network of over 10 000 distributors and dealers Service support is just a phone c...

Page 2: ...e with covers shrouds or guards removed A CAUTION Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock dh WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Before ser...

Page 3: ...head will require more frequent service See Required Maintenance on page 7 Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Koh...

Page 4: ...king again turn plug all the way into crankcase With extended oil fill tube and dipstick push dipstick all the way down in tube then take reading F t I lM Operating Range 1 r L NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Changing Oil For a new en...

Page 5: ...ression STOP Return starter handle pull firmly with a smooth steady motion to start Pull the handle straight out to avoid excessive rope wear from the starter rope guide Extend the starting rope periodically and check its condition If the rope is frayed have it replaced immediately by your Kohler Engine Service Dealer a WARNING Accidental Starts Before extending and checking the retractable starte...

Page 6: ...OTE If debris builds up on air intake screen other intake areas STOP the engine immediately and clean Obstructed air areas cause engine damage due to overheating A WARNING Hot Parts Engine components can get extremely hot from intake operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shield...

Page 7: ...Supply DAILY Service Precleaner 25Hm ChangeOil 25Hf Check ReductionGear Unit 50Hlls Clean Cooling Fins and ExternalSurfaces 50 Hrrr Replace Air Cleaner Element 100Hrs Check Spark Plug Condition and Gap 100 Herr Have Breaker Points Checked2 500 Hrs HavelgnitionTimingChecked2 H Have Valve and Tappet Clearance Checked2 500 Hra HaveCylinderHeadsServiced2 5OOHrs Have Starter Motor Drive Serviced2 500 H...

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Page 9: ...fully bending the ground electrode Install the plug and torque to 18 22 ft lb 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and e...

Page 10: ...skets in good condition Make sure the air cleaner element is clean and all air cleaner components are fastened securely after checking the items listed above starting or engine operation problems exist it may be necessary to adjust or service the carburetor NOTE Carburetor adjustments should be made only after the engine has warmed up Kohler Carburetor Adjustment 1 With the engine stopped turn the...

Page 11: ...for the Basic Engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed must not exceed 1500 RPM Walbro Carburetor Adjustment 3 Idle SDeed Screw Main Fuel Needle In general turning the adjusting needles In clockwise decreases the supply of fuel to the carburetor This gives a leaner fuel to air mixture Turning the adjusting needles out counterclockwise incr...

Page 12: ...ing needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle L Back out Appx 118 to 114 Lean turn Lean CI I I I I I I I I v c3 Optimum Low Idle Fuel Settlng Low Idle Speed Setting Place the throttle control into the idle or lown position Set the low idle speed to 1200 RPM or 75 RPM by turning the low idle speed adjustin...

Page 13: ...X X X X X X BAlTERY CHARGING REDUCTION GEAR UNITS A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewe ty when servicing batteries On engines...

Page 14: ...ore use the following storage procedure 1 2 3 Clean exterior surfaces of the engine Change oil when engine is stillwarm from operation See Changing Oil on page 4 Drain reduction gear unit if so equipped and refillwith same oil as used in engine for season of operation 4 The fuel system must be completely emptied or the gasoline must be treated with a stabilizerto prevent deterioration If you choos...

Page 15: ...park Plug Gap Spark Plug Size 14 mm Spark Plug Type Champion RJ8C or equivalent 5 2 kW 16 9 in3 277 cm3 2 938 in 74 62 mm 2 500 in 63 50 mm 65 lb 29 5 kg 2 5 U S pints 1 2 L 0 025 in 0 65 mm Breaker Point Gap Nominal 0 020 in 0 50 mm Power Ratina at3600RPM 8hp v 6kW Displacement Bore Stroke Approx Weight Oil Capacity 18 6 in3 305 cm3 2 938 in 74 62 mm I I 2 750 in 69 85 mm 65 lb 29 5 kg I a 0 I I ...

Page 16: ... SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts ANY IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRIT TEN WARRANTY anyone authorized to make any...

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Page 154: ...METER HOW TO PREPARE A DRY CHARGED BATTERY FOR SERVICE PROCEDURE FOR TESTING BATTERIES SECTION II CHARGING SYSTEM ALTERNATOR CHARGING SYSTEMS KOHLER ONAN ENGINES BRIGGS STRATTON ALTERNATOR SYSTEMS TECUMSEH 7 AMP REGULATED CHARGING SYSTEM LT 1032 SECTION III COMPONENTS SECTION IV WIRING DIAGRAMS SECTION V TROUBLE SHOOTING EXAMPLES ...

Page 155: ...CTRICAL SERVICE PART NO 810291R2 Printed in U S A 0385 ...

Page 156: ...al components and wiring diagrams CONTENTS SECTION I BATTERY 1 5 How It Works 1 How To Use a Hydrometer 2 How To Prepare a Dry Charged Battery 3 Procedure For Testing Batteries 4 Page SECTION II CHARGINGSYSTEM 6 10 Alternator Charging Systems Kohler 6 SECTION III COMPONENTS 11 16 Onan Engines SECTION IV WIRING DIAGRAMS 17 40 SECTIONV TROUBLESHOOTING EXAMPLES 41 47 I ...

Page 157: ...sulfuric acid remains in the electrolyte The gradual weakeningof the electrolyte lets us measure with a hydrometer the amountof unused acidin the water and thushow much potential energy is left i FULLY CHARGED GOING DOWN Acid in water gives electrolyte As battery discharges acid specific gravity of 1 265 begins to lodge in plates Specific gravity drops END LIFE DISCHARGED Battery half discharged A...

Page 158: ...INACCURATE READINGS The float should not touch any part o f the barrel A full charge battery equals 1 265 specific gravity Spg unless otherwise specified Replace battery if there is 50 0 050 or more points variation between highest and lowest cell Spg varieswith temperature so for correct readings the electrolyte temperature should be at 60 F or higher High float left means high Correct method of ...

Page 159: ...a t t e r y i n the vehicle C F i l l withelectrolyteuntil i t becomes v i s i b l e a t bottom of filling tube D A l l o w battery t o standfor 15 minutes a t room temperature beforecharging E Place on charger for 10 minutes a t a 15 amp r a t e I f a fastratechargerisnotavailablechargefor one half hour a t a 7 amp r a t e F Aftercharging check acidlevelsinallcells and f i l l withacid t o the to...

Page 160: ...r o l y t e terminal damage Obvious Damage No Obvious Damage Replace I Check e l e c t r o l y t e level I Below top of plates in one or more c e l l s E l e c t r o l y t e level above top of p l a t e s i n a l l c e l l s Proceed Step 2 Add water to proper level Charge f o r 15 min 15 25 amps withnon safetyvent caps removed ProceedtoStep 2 4 ...

Page 161: ...t cell variation between highest and lowest cell Recharge battery If 50 points variation persists replace battery Specific Gravity Below 1 225 Charge untilall cells are at least 1 225 if unable to obtain Specific Gravity1 225 in all cells replace battery 5 Specific Gravity Above 1 225 Battery OK ...

Page 162: ... includes an alternator stator and permanent magnet ring inside the fly wheel With the exception of the magnet ring which revolves around the stator these systemshave no moving parts and are therefore virtually service free the only required service is an occasional checkto make sure that all electrical connec tions are tight and that wires are not frayed or cracked FUSE ALTERNATOR OUTPUT SOLE I I...

Page 163: ...Continuously Charges atHigh Rate Test C Check B to ground with DC volt meter C 1 If over14 7 volts C 2 If under14 7 Possible Fault Remedy A 1 Indicates alternator System OK battery was fully charged 4 2 Check for defective stator orrectifier regulator Test B Possible Fault Remedy B 1 Defective stator replace B 2 Defective rectifier regulator replace with new unit Possible Fault Remedy C 1 Rectifie...

Page 164: ...ne speed so the brightness of the light changes with the engine speed The current from the battery charging alternator is unregulated and is rated at3 amps The output rises from2 amps at 2400 RPM to 3 amps at 3600 RPM and uses less than 2 of a horsepower There is one external connection The battery charging current connection is made through one terminal of a two connector plug Current for lights ...

Page 165: ... in either direction the diodeis defective and must be replaced D Testing Stator Charging Coils Remove blowerhousing flywheel etc and examine red lead wire for cuts damaged insulationor obvious shorton leads if bare spots cannot be repaired replace stator Stator should also be checked for continuity as follows Use multimeter set on resistance scale Touchone meter lead to stator laminations touch t...

Page 166: ... for these engines with the following exceptions Test B AC voltage value should be at least 21 VAC The blower shroud must be removed the rectifier regulator moved to place it outside the housing and the blower housing reinstalled to make this test Test C Do not perform this test If AC voltage check is OK and battery is not being charged replace the rectifier regulator 10 ...

Page 167: ...SECTION I I I COMPONENTS 3 ...

Page 168: ...982 A B LT GT SERIES 1983 Fig 3 LIGHTSWITCH AND FUSE ALL TRACTORS WITH LIGHTS FUNCTION Turns Lights On or Off B CSERIES B C LT GTSERIES 1978 81 1982 83 FUNCTION Protects Light Circuit Wiring From Heat When An Electric Short or Overload Occur Fig 4 12 ...

Page 169: ...F i g 5 NORMALPOSITION F i g 8 Normally closed N C S w i t c h F i g 9 Normally closed N C S w i t c h ...

Page 170: ...Fig 10 Fig 11 14 ...

Page 171: ... SWITCH 6 SERIES1981 I FUNCTION GroundsEngine Magneto When D C Current To Internal Coil is Cut Off TRANSMISSION SWITCH A SERIES1981 1982 N O SILVER A 51 1982 A 81 A 111 1983 N O N C PINK WIDE TERMINAL N C NARROW TERMINALS FUNCTION Prevents Engine From Starting With Transmission In Gear Fig 13 15 ...

Page 172: ...SECTION IV WIRING DIAGRAMS WIRING DIAGRAM 1981 A 51 and A 81R RECOIL START RIDER IGNITION SWITCH INTERLOCK MODULE RED ENGINE PTO INTERLOCK SWITCH INTERLOCK SWITCH Fig 14 17 ...

Page 173: ...F i g 15 18 ...

Page 174: ...I I K a W I K I a W ...

Page 175: ...I f Fig 17 20 ...

Page 176: ...W W a 3 Fig 18 21 ...

Page 177: ...a F i g 19 22 ...

Page 178: ...W W 3 a Fig 20 2 3 ...

Page 179: ...A K W a I E K a a m K ow K m 3 w w K 3 a K w Fig 2 1 24 ...

Page 180: ...K W Fig 22 2 5 ...

Page 181: ...K w K Fig 23 26 ...

Page 182: ...Fig 2 4 27 ...

Page 183: ...a W a I I I I Fig 25 28 ...

Page 184: ...Fig 26 2 9 W ...

Page 185: ...D WHEN TRANSMISSION CLOSEDWHEN SEATUNOCCUPIED ORANGE CONTACTS CLOSEDWHEN TRANSMISSION IN NEUTRAL ORANGE PTOINTERLOCK SWITCH CONTACTS CLOSED WHEN BLUE WHITE ALTERNATOR DC OUTPUT ALL WIRES BLACK WITH COLOR STRIPE ASSHOWN ENGINE CHARGINGSYSTEM IS OPERATION NOT DESIGNED FORACCESSORY START CIRCUIT ...

Page 186: ...CK SWITCH CONTACTS CLOSEDWHEN TRANSMISSION IN NEUTRAL PTO INTERLOCK CLOSED WHEN CONTACTS PTO DISENGAGED WHITE CONTACTS TRANSMISSION CLOSED WHEN IN GEAR ORANGE ORANGE CLOSEDWHEN CONTACTS BLACK CLOSED WHEN MAGNETO ALL WIRES BLACK WITH COLOR STRIPE AS SHOWN ENGINE CHARGINGSYSTEM IS OPERATION NOT DESIGNED FOR ACCESSORY KILL CIRCUIT PTO ENGAGED ...

Page 187: ...ECTRICAL POSITION BETWEEN TERMINALS ACCESSORIES A G SWITCHCASE GROUNDED RUN START B S BLUE IGNITION SWITCH CONTACTS TRANSMISSION CLOSED WHEN SEAT UNOCCUPIED ORANGE CONTACTS CLOSED WHEN I BLUE BLUE WHITE ALTERNATOR DC ALL WIRES BLACK WITH COLOR STRIPE ASSHOWN ENGINE CHARGINGSYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION KILL CIRCUIT TRANS IN GEAR ...

Page 188: ...CTS CLOSEDWHEN TRANSMISSION IN NEUTRAL PTO INTERLOCK SWITCH CLOSED WHEN PTO DISENGAGED SWITCH CONTACTS CLOSED WHEN TRANSMISSION IN GEAR CONTACTSCLOSED WHEN ORANGE ORANGE CONTACTS CLOSEDWHEN PTOENGAGED BLUE WHITE ALTERNATOR MAGNETO D C OUTPUT ALL WIRES BLACK WITH COLOR STRIPE ASSHOWN ENGINE CHARGINGSYSTEM I S NOT DESIGNED FORACCESSORY OPERATION CHARGINGCIRCUIT 33 ...

Page 189: ...Fig 27 34 ...

Page 190: ... I K I a W I I W I Fig 2 8 35 ...

Page 191: ......

Page 192: ...K W w K Fig 30 37 ...

Page 193: ...K W a d K Fig 31 38 ...

Page 194: ...I Fig 32 39 ...

Page 195: ...K 40 ...

Page 196: ...EM 1 Customer Complaint Every time he uses his C 85 1981 tractor it won t start He has to put jumper cables on the battery and jump start the tractor Fig 34 STEP 1 Visually Inspect A l l Connections A Blown Fuse B Loose or Broken Wires Fig 35 ...

Page 197: ...linspection B Charge the battery C Hydrometertest Fig 36 Step 3 If battery checks out OK and tractor will now start with fully charged battery check the following A Start unit and check charging sys tems 1 Ammeter for Charge Fig 37 42 ...

Page 198: ...ltage should show increase to approximately 14 volts D C Fig 38 Step 5 No voltage increase unplug the rectifier regulator with the meter set for A C current the meter should read around 28 volts AC if less than 28 volts A C Defective stator replace if more than28 volts A C Defective rectifier regulator replace withnew unit Fig 39 43 ...

Page 199: ...81 GT 2500 Anniversary Special the engine cranks over but won t start After some investigation you find the battery is in good condition Fig 40 Step 1 Always check the obvious A Blown Fuse B Loose or Broken Wire Connection Fig 41 44 ...

Page 200: ...Step 3 i NOTE Remember you will have to reconnect the magneto wire to kill the engine B If it doesn t start the problem is with the engine not the wiring harness 1 Check the engine for spark if spark there is some carburetor or mechanical problem 2 If no spark check breaker points and magneto Fig 42 ...

Page 201: ...ll relay circuit First connect a test light or meter to the black wire located on the ignition switch I terminal Try starting the unit If we show voltage continue to Step 4 Fig 4 3 Step 4 Inspect the connections to the kill relay and PTO interlock switch Make sure the kill relay has a good ground Fig 44 Fig 45 ...

Page 202: ... 5 Connect a t e s tl i g h to rm e t e rt ot h e k i l l r e l a y s t e r m i n a lv i o l e tw i r e t r ys t a r t i n g t h e u n i t i f you show current replacethe k i l lr e l a ys w i t c h Fig 46 ...

Page 203: ...Inc reserves the right to Product information and specifications are shown herein as of the changeproductspecifications designsandstandardequipmentwithout notice and without incurring obligation WHEEL HORSE WORK HORSE Iawn gardentractors by ...

Page 204: ...AUTOMATIC TRANSMISSION REPAIR MANUAL SUNDSTRAND HYDROSTATIC SYSTEMS Hydrogear Piston Piston 1965 1982 Part No 492 4206 Formerly A 1391 803402 ...

Page 205: ... 1965 to mid 1973 hydrogear units Pages 54 56 and mid 1973 to 1977 piston piston units Pages 60 62 Be sure to check parts price list to determine if all parts needed are still available before ordering parts Piston piston part numbers for 1978 82 model year tractors are contained in the particular tractor parts manual D Series Adjustments Transmission control linkage adjustments described in this ...

Page 206: ...s Keep in mind an unsealed conditionanywhere in the transmission will cause a low or no charge pressure condition Troubleshooting charts and the lack of charge pressure seem to point to the pump section as the sourceof the problem Experience shows most lossof pressure conditions to be due to sticking acceleration or forward reverse check valves charge pressure relief valves o r a problem in the mo...

Page 207: ...dowelpin into the housing Be sure the valve plate notch is over the dowel pin on assembly or the valve plate willbe ruined Control Shaft Stub Shaft On 1978 and later transmissions the longer control shaftis used on both sides of the pump housing Fig 57 Using a later transmission on an earlier tractor may require cutting a clearance holein the tractor s sheet metal for the longer shaft Acceleration...

Page 208: ...to gainaproperunderstanding of the Wheel Horse automatic transmission The automatic transmission is a sophisticated piece of machinery Maintainstrictcleanlinesscontrolduringallstages of serviceand repair Even a small amount of dirt or other contamination can severely damage the system Although this manual dealsprimarilywiththeSundstrandpiston piston type hydrostatic transmission service and repair...

Page 209: ... SYSTEM NEUTRAL ADJUSTMENT FRICTION ADJUSTMENT SPEED CONTROL LINKAGE AND ADJUSTMENTS SEPARATED SYSTEM 1973 18 HP AUTOMATIC NEUTRAL ADJUSTMENT FRICTION ADJUSTMENT PARKING BRAKE ADJUSTMENT 1974 D SERIES TRACTORS NEUTRAL ADJUSTMENT FIG 8 LEVER POSITION ADJUSTMENT FRICTION ADJUSTMENT SPEED CONTROL LEVER FRICTION ADJUSTMENT PARKING BRAKE PARKING BRAKE ADJUSTMENT 1975 D SERIES TRACTORS NEUTRAL ADJUSTMEN...

Page 210: ...ND MOTOR SHAFTS CYLINDER BLOCK ASSEMBLIES GENERAL CYLINDER BLOCK FACE PISTONS AND SLIPPERS SLIPPER RETAINERS VALVE PLATES THRUST PLATES CHARGE PUMP ASSEMBLY BEARINGS FOR REPLACEMENT SEE DISASSEMBLY AND ASSEMBLY SECTION DISASSEMBLY ASSEMBLY OF HYDROSTATIC PUMP PUMP HOUSING DISASSEMBLY ASSEMBLY DISASSEMBLY ASSEMBLY OF PUMP HOUSING ASSEMBLY OF PUMP SECTION REMOVAL REPLACEMENT OF ACCELERATION VALVES D...

Page 211: ...AR TUNE UP HYDROGEAR SERVICE NOTE HYDROGEAR HYDROGEAR PARTS DRAWING LIST 1965 73 PUMP SHAFT SEAL REPLACEMENT THE TRANSAXLE REMOVAL OF TRANSAXLE COMPLETE WITH HYDROSTATIC UNIT REMOVAL OF HYDROSTATIC UNIT FROM THE TRANSAXLE TRANSAXLE DISASSEMBLY PARKING BRAKE AND OIL FILTER TRANSAXLE GASKET INSTALLATION PISTON PISTON HYDROSTATIC TRANSMISSION 1973 1977 SERVICE BULLETIN RECORD ...

Page 212: ...GE AND ADJUSTMENTS Separated System 19 Neutral Adjustment 19 Friction Adjustment 20 Parking Brake Adjustment 20 NeutralAdjustment 22 Lever Position Adjustment 22 Speed Control Friction Adjustment 22 ParkingBrake Friction Adjustment 23 ParkingBrakeAdjustment 23 Neutral Adjustment 23 Lever FrictionAdjustment 23 ParkingBrakeAdjustment 23 1973 18 HP Automatic 1974 D SeriesTractors 1975 D Series Tracto...

Page 213: ...al 27 INSTALLATIONOFHYDROSTATICUNIT IN A SEPARATED SYSTEM 27 Pump Installation 27 Manifold Installation 28 Motor Installation 30 INSPECTIONOFPARTS 32 Pump andMotor Shafts 32 Cylinder Block Assemblies 32 Cylinder Block Face 32 Pistons and Slippers 32 Slipper Retainers 33 Valve Plates 33 Thrust Plates 33 Charge Pump Assembly 33 Bearings 33 DISASSEMBLY AND ASSEMBLY OF HYDROSTATIC PUMP 34 PUMP HOUSING...

Page 214: ...arTune up 49 Hydrogear Service Note 50 Check Valves 51 Charge Relief Valve 52 TowingValve 52 Implement Relief Valve 52 Hydrogear Removal and Replacement 52 HYDROGEAR TRANSMISSION PARTS DRAWING 54 HYDROGEAR PARTS LIST 55 HYDROGEAR PUMP SHAFT SEAL REPLACEMENT 56 THETRANSAXLE 57 Removal of Transaxle Complete with Hydrostatic Unit 57 Removal of HydrostaticUnit from the Transaxle 57 Transaxle Disassemb...

Page 215: ...With the con trol lever in neutral oilis under low pressure through outthe circuit When the controllever is advanced the circuit pressureincreases causingthe oil on the high pressure side to bleed by the flatson the valve lands andinto the low pressure side This high pres sure oil continues tobleed to the low pressure side by passing the piston motor and holding the accelera tionrate to a safe lev...

Page 216: ...FIG E i a a I I C e I a m e W ...

Page 217: ...FIG 2 K I I 7 ...

Page 218: ...FIG 3 ...

Page 219: ...eck 1 Transmission oil level 2 Speed control linkage page 19 3 The push valvemake sure it is closed page 5 SPECIAL SERVICE NOTE If thetractordrives in the wrong direction when the control lever is moved the hydrostatic motor cover was in correctly installed 180 off position by the supplier Turn it to the cor rect position see page 42 step 4 TRACTOR WILL NOT OPERATE IN EITHER DIRECTION ENGINE BOGS ...

Page 220: ... OK NOT SEATED DEFECTIVE SERVICE AREA Push Valve Motor valve plate Pump valve plate Countershaft keys Speed control linkage Transaxle gears GENERAL INFORMATION Page 5 Page 33 Page 33 Page 19 REPLACE THEN REPAIR SPEEDCONTROLLINKAGE OUTPUT SHAFT GEAR OUT O F MESH I REPAIR REPAIR REMOVAL REPLACEMENT Page 43 Page 35 Page 57 Page 57 ...

Page 221: ...T BE PUSHED WITH PUSH VALVE CLOSED CONTROL LINKAGE INSPECT HYDROSTATIC SHAFTROLLPINS DEFECTIVE NOT TURNING REPLACE SERVICE AREA GENERALINFORMATION REMOVAL REPLACEMENT Speed control linkage Pump shaft Control shaft roll pins Page 19 Page 34 Page 37 Page 37 1 1 ...

Page 222: ...RECTION ONLY INSPECT NTROL DEFECTIVE REPAIR OR REPLACE DEFECTIVE REPLACE DEFECTIVE REPLACE SERVICE AREA GENERAL INFORMATION REMOVAL REPLACEMENT Speed ol linkage Page 19 Charge check valves Page Acceleration valves Page 5 Page 40 ...

Page 223: ...E I I DEFECTIVE SERVICE AREA Acceleration valves Charge check valves Seal rings standard system Seal rings separated system Shaft seals Motor cylinder block Swash plate roll pins GENERAL INFORMATION Page 5 Page 32 Page 32 REMOVAL REPLACEMENT Page 40 Page 36 Page 26 Page 29 Page 37 44 Page 43 Page 37 13 ...

Page 224: ...AMINATED CLEANSYSTEM AND REPLACE OIL I J I LOW DEFECTIVE RELIEF VALVE DEFECTIVE O K INSPECTIMPLEMENT RELIEF VALVE DEFECTIVE INSPECT COVER MISSING INSTALLTHRUSTPLATE AND REPLACECYLINDER BLOCK ASSEMBLY THRUST PLATE O K O K O K INSPECT PISTON W O R N REPLACE CYLINDER BLOCKASSEMBLY O K INSPECTCYLINDER BLOCKASSEMBLY DEFECTIVE O K I I O K ...

Page 225: ...hrust plate Hydrostatic motor Slipper retainers Piston slippers Cylinder block assembly Parking pawl Transaxle gears GENERAL INFORMATION Page 24 Page 33 Page 5 Page 5 Page 33 Page 32 Page 32 REMOVAL REPLACEMENT Page 35 43 Page 35 Page 35 Page 42 Page 41 Page 46 Page 46 Page 46 Page 58 Page 57 15 ...

Page 226: ...ELIEF VALVE DEFECTIVE O K INSPECTMOTORCOVER THRUSTPLATE INSTALLTHRUSTPLATE A N D REPLACE CYLINDER BLOCK ASSEMBLY O K INSPECT HYDROSTATIC O K INSPECT SLIPPER RETAINERS DEFECTIVE REPLACE I o k INSPECT PISTON REPLACE CYLINDER BLOCKASSEMBLY O K INSPECT BLOCK ASSEMBLY CYLINDER DEFECTIVE OK INSPECTPARKING REPAIR OR REPLACE I I O K GEARS BROKEN REPLACE INSPECTTRANSAXLE ...

Page 227: ...rgerelief valve Implementreliefvalve Motor thrust plate Hydrostatic motor Slipper retainers Piston slippers Cylinder block assembly Parking pawl Transaxle gears GENERAL INFORMATION Page 34 Page 5 Page 5 Page 24 Page 5 Page 5 Page 33 Page 32 Page 32 REMOVAL REPLACEMENT Page 40 Page 26 Page 27 Page 35 Page 35 Page 42 Page 41 Page 46 Page 46 Page 46 Page 58 Page 57 17 ...

Page 228: ...y six pounds of force at the handle cam pin until the rear wheels stop turning The proper amount of friction is obtained when forwardandbackward wheelrotation movesthe control lever Be sure totighten thelock The lobe On the eccentric pin must be nut after proper tension is achieved The friction collar up for proper operation is self lubricating and does notrequirelubrication the access plate SPEED...

Page 229: ...adedtohold selected speed in either direction If the lever does not remainwhereit is set during operation the friction may be increased by tightening the adjusting nut through the access hole located in the right panel see Fig 6 The proper amount of friction is obtained 1 With the engine shut off press and releasethe brake pedal 2 Engagethe parkingbrakebyplacing the lever in the rear notch of the ...

Page 230: ...1974 D SERIES TRACTORS NEUTRAL ADJUSTMENT 6 43 6 27 6 25 6 28 6 22 6 21 FIG 8 Brake SpeedControl linkage 1974 D Series 21 ...

Page 231: ... Be sure to check both tires This usually occurs at apointmidway between forward andbackwardwheel rotation 5 Retighten the set screw If the speed controllever does notreturnrothe neutral center position when the brake pedal is depressed adjust as follows 1 Remove the top cotter pin retaining the shift 2 Rotatethe shiftrod checking periodically until the speed controllever is centered when the brak...

Page 232: ...ntric cam pin to a point midway between forward wheel rotation and backward wheelrotation Retightenthelockscrew hold ing the eccentricassembly 5 Increase engine speed to full throttle Move the speed control lever in both directions and re turn it to neutral with the pedal Repeat several times Recheck adjustment and readjust if required To position the speed control lever at the neutral position of...

Page 233: ...everse CHARGEPRESSURE TEST Charge pressure is an indication of transmission condition Connect the pressure gauge as shown in Fig 13 to the 1 4 pipe plug located between the imple menthoseports The alternateport straightthread just above this portmaybe used if it is morecon venient With the engine runningat 3 4 throttle thecharge pressureshould be 70 to 150 PSI The pressuremust never drop below50 P...

Page 234: ...ransmission As installed ina Standard System be 550 to 700 PSI when the piston hasreachedthe end of its stroke REPAIRPROCEDURES On B and C Series tractors and other standard systemtractors the hydrostaticpump and motor are bolted together as one unit Fig 15 On the 1973 18 HP Automatic and all D Series tractors the pump and motor are separated to accommodatethe design incorporating a manifold betwe...

Page 235: ... the belt guardand remove the drive 5 Remove the access pump 6 Remove the two bolts and nuts at the top of theassembly and the two cap screws onthe bottom Carefully remove the pump and motor assembly from the transaxlemaking surethe cam block pin disengages from thecam block Remove the old gasket andall traces of dirt and oil assembly belt from thetransmission pulley INSTALLATION OF HYDROSTATIC UN...

Page 236: ... to neutral just as it is when operated by the speed control lever On some models a third rod at the rear connects the neutral plateand the parkingbrake lever Remove the four 5 16 cap screws holding the frontmanifoldpad to the pump pad As the two rear screws have elasticstopnutsonthe top itwill be necessary to hold them while removing the screws An oildrainpan should be placedunderthisarea since t...

Page 237: ...h moly grease and top butdo nottightenat this time Remove the two slide the enginecarefullyto the rear Engagethe pump spline with the pump coupling centerthe engineon the pump shaft andbolt the engine securely to the frame Connect engine controls as required and install and connect the battery Install the grille shroud and hood After checking the oil level filling as required test the unit for pro...

Page 238: ...olt does not use a washer The front 1 2 bolt however requires FIG 30 Positioning the Manifold a specialsealwasher Also an O ring is used at this corner between the manifold and the motor pad These extra seals arerequired since this bolt goes downintoa pressurearea If it is notsealed there will be amajoroil leak Before installing sealrings placeasmallamount ofgrease in each recess and on all sealri...

Page 239: ...l the two longer bolts in the two rear holes with the elastic stop nuts on top Tighten all four bolts evenly holding thenutsonthe rearbolts as required Nowtighten all four of the rear manifold pad to motor bolts FIG 34 Seat Pivot Installation FIG 32 Manifold Installed Install theseat spring on its support and install the spring blockon top ofthe spring Line up the adjustmenthandle at the rear ofth...

Page 240: ...is installed around the right frontbolt hole located at the top left cornerofthe following photograph Center a square section back up ring on top of each of the large O rings and install them in the two large high pressure ports When properly installed the bottom of the back up rings will be just below the topof the recess Be verycarefulnotto get dirt onthe pad surface To install the motor line it...

Page 241: ... valving surface worn 3 Scored piston barrels 4 Slipperedges rounded more than 1 32 inch When inspectingcylinderblock assemblies always scratchedorscored return pistons to their original cylinder bores Check to make sure the pistons move freely in their bores Carefully remove each piston and check for scores onthe pistonbarrelsand onthe cylinder bore walls Replace with cylinder block kit if bores ...

Page 242: ...t Plates Charge Pump Assembly Inspect the gerotor set internal and external rotors and the housing for wear and scoring Replace as required Note The gerotor set is a matched unit Alwaysreplace as an assembly If thecharge pump housing is worn or scored it must be replaced FIG 44 Bearings for replacement see Disassembly and Thrust Plates Examine the needle bearings in the pump and motor Assembly sec...

Page 243: ...ap 2 With the pump assembly held horizontally carefully removethe finned aluminum pump housing together with the input shaft swashplate and cylinder block assembly Note Make surethe cylinder block and piston assemblydoes not drop off the input shaft The valve platemay stick to the cylinder block and come out with it or it may stickonthecharge pump housing 3 Remove the pump housing pump end cap gas...

Page 244: ...the position dowel pin down of thecharge pump assembly in relation to theend cap FIG 51 Pump End Caps 8 Remove the 5 8 hex plug from the top left corner of the pump endcap Top left means viewed from themotorside of theendcap See Fig 51 If FIG 49 the unit is equipped for hydraulic lift operation re move the charge ball valve and spring from the pump end cap top view If the unit is not equippedfor 5...

Page 245: ...he pump end cap Viewed from the motor side of the pump end cap see Fig 52 If the unit is equipped forhydraulic lift operation there will be shims located in the spring cavity of the plug Do not lose these shims as they determine the amount of implement pressure Remove the spring and cone valve Do not mix up this implement valve spring with the charge valvespringremoved from thetop left corner 10 R...

Page 246: ...e 7 Remove the swash plate housing 8 Pryoutthe trunnion seals beingcarefulnot to damage the housing Note If examination of the trunnionshaft needle bearings and the pumpshaft ball bearing shows them to be in good condition steps 9 and 10 should notbeperformed 9 Using asuitablearbor such as a socket press or drive needle bearings out of thehousing from the inside FIG 55 Seal Removal 2 Remove the pu...

Page 247: ...on th e free wheeling valve making sure the seal is toward the pump housing and the split back up ring is toward theoutside Install the valve assembly FIG 59 Needle Bearing Installation 3 Install newtrunnionshaft seals pressingthem in until they touch bottom Oil the seal lips with 1OW30 engine oil 4 Insert the swash plate assembly into the case Slide the trunnion shafts into each side andinto the ...

Page 248: ...plug and 0 ring in the top left corner of the pump end cap 2 Install thecone valve and spring in the top right corner of the pumpend cap then making sure that the original shimpack is in the spring cavity of theplug install the plug 0 ring and shimassembly FIG 62 Charge Pump Assembly 4 Install the gerotor set in thecharge pump hous ing and install the pump housing and gerotor assem bly onthe pump ...

Page 249: ... the pump housing in place itmaybe necessary to turn the pump shaft to align it with the charge pump spline After the housing and shaft are pushed in place tighten the four bolts evenly 9 Center the charge pump gerotor drive so the pump shaft and spline can enter it REMOVAL REPLACEMENT O F ACCELERATIONVALVES NOTE Although the acceleration valves look similar they arenot alike The forward valve loc...

Page 250: ... plug andinstall the spring and meteringplug 41 4 Install the forward accelerationvalve assembly the one with the wider relief flats in the bore at the rear of the end cap housing Insertthereverse accelerationvalve assembly the one with the narrow relief flats together with the spring intothe bore at the front of the end cap housing Make surethe spring seats in the springcavity of each valve When ...

Page 251: ...emove the four 3 8 16 cap screws thatretain the aluminum housing to the motorend cap main iron housing and remove the aluminum housing Note the positionof thehousing I t must beinstalled with thewebbed sectionup If thecover is reversed the FIG 74 Motor Housing unit will operate in the opposite direction 5 Re move the housing to end cap gasket 6 Remove the thrustplate from the fixed swash 7 Remove ...

Page 252: ...etainingspring clip popsloose from the retainer in thecenter of the cylinder block This pressing opera tiononlyrequiresmoving the shafta shortdistance CAUTION DO not press the shaft through the cylinder block at this time 11 Remove the assembly from the press andre movethe cylinder block FIG 77 Remove SpringRetaining Clip 12 Remove the spring retaining clip from the 13 Remove the motor shaft from ...

Page 253: ...tNeedle Bearing with Seal Retainer B Installation Install the first needle bearinginto the output end of the motor end cap with the lettered end of the bearing out Press the bearing in to the flush point Thenpresstheseal retainer insert in until it is flush with the end cap FIG 82 Install secondNeedle Bearing Install the second needle bearinginto thecy linder block end of the end capand pressing a...

Page 254: ...y 7 Slide the cylinder block pistons slippers and slipper retainer assemblyonthemotorshaft Push it in place until the springretainingclip seats 8 Install the ball bearing in theendofthe alumi numhousing with letteredend out 9 Install the four 3 8 16 cap screws through the aluminum housing and installa newgasketoverthe bolts 10 Install the thrust plate on the swash plate surfaceofthehousing 11 With...

Page 255: ...nd of the bolt and tighten the nut until the spring is compressed roloc retaining ring 4 With the spring compressed remove the spi 5 Loosen and remove thecompressor and remove the outside retaining washer spring and inside spring seat NOTE The pumpcylinder block incorporatesa flat washer for the inside spring seat The motor cylinder block incorporates aspecial spring seat retainer which also serve...

Page 256: ...HYDROGEAR SECTION 47 ...

Page 257: ... 48 ...

Page 258: ...rouble causing condition The trouble shooting chart indicates possiblecauses and test or corrective procedures for the fivetrouble conditions listed above The HydrogearTune uppro cedures are recommended as a correction in several cases HYDROGEAR TUNE UP CAUTION Cleanliness is oneofthemost important considerations during every step of the Hydrogear tune up Instead of repeating a cleanliness precaut...

Page 259: ... in Step 1 across the large vertical passage and deter mine if the internalplug is in place 3 If the internal plug is in place but is loose tighten it securely and replace the side plug 4 If the internalplug is not in place use a 7 16 Allen wrench to remove the topplug a The internal plug is usuallyfound at the bottomof the large vertical passage Retrieve it with a magnet 5 Insert the internalplug...

Page 260: ... either part is severely scored both must be replaced They are serviced as a matched set Sticky piston operation can be corrected bylightly polishing the piston and bore of the sleeve with Crocus cloth The piston to bore clearance is extremely close therefore the pistonmaynot pass through the sleeveunder its own weight Remove the 0 rings from the sleeve and discard them Wash piston and sleeve with...

Page 261: ...he seat in thecentersection for nicksorsigns of erosion If it is badly eroded the Hydrogear assembly must be replaced Clean theparts with solvent and coatthem with type A automatic transmission fluid Installanew 0 ring onthe plug 7 Fig 90 using care not to damage it on thescrewthreads Insertthe spring in thevalveandinstall the assembly valve first into its boreon the front of thecentersection Inst...

Page 262: ... lift transfer the implement relief valve from the replaced Hydrogear to the new assembly Fig 97 and con nectthe hydraulic hoses Completethe tightening of tool boxassembly FIG 95 Remove the strainer Fig 96 and clean with sol vent and compressed air The strainer contains a magnet to retain metal particles circulated by the fluid Installation Clean the gasketsurfaceonthesideofthe trans axle Make sur...

Page 263: ...HYDROGEAR PARTS DRAWING 1965 73 ...

Page 264: ...Seal 11 8I D Seal Brake Shaft1 2 1 D Pin Dowel Case L H Bearing Needle1 I D End CapR H End CapL H Axle Rear R H Axle Rear L H Snap Ring Washer Thrust Gear Axle Gear Differential Ring Body Roll Pin 1 4 x 1 2 Gear Differential Pinion Spring Cylindrical Bolt 3 8 16 X 3 1 4 Nut Elastic Stop 3 8 16 Washer Flat 3 8 SAE Gear 44Teeth 11 Teeth Gear 22Teeth Gear 33Teeth Shaft 1 Dia Snap Ring 1 Shaft Key 9Wo...

Page 265: ...his itwill also be necessary to remove the R H foot rest on these models Loosen the belt tension by setting the parking brake and remove the beltfrom the shaft pulley Remove the pulley and Woodruff key from the input shaft NOTE It is extremely important not to damage the shaft orthesoft aluminum housing The follow ing steps should be done verycarefully Slide asmall hook tool orscrew driveralong th...

Page 266: ...ntrol cam comes free from thecam pin ball stud Now the magnetic strainer is accessible FIG 98 Hydrostatic Unit Gasket Strainer and Transaxle Remove the strainer and wash with solventw hen ever servicing the transaxle Check the magnet at the endof the strainer for metal particles If metal particles are found carefully inspectthe internal parts of the hydrostaticunit for damage TRANSAXLEDISASSEMBLY ...

Page 267: ...There fore thepositions of diagonally opposite pinions are the same see photo FIG 102 Pinion Gear Placement 10 The axle gears may be separated from the axleby removing the snap ring NOTE During re assembly tighten all bolts securely in sequence PARKINGBRAKE AND OIL FILTER 1 To replace the oil filter remove by turning counter clockwise This throw away filter should be replacedevery year or every 10...

Page 268: ... Remove thewoodruff key and file any rough edges from the key slot and the endof the axle 3 Remove the tractor seat and fender assembly by removing the hardware holding itto the transaxle Remove the footrestbracketand the beltguard as sembly and remove the drivebeltfrom thetrans mission Remove any access plates 4 Disengage the spring from the parking brake Remove the rear hitch 5 Remove the two ca...

Page 269: ...Parts Drawing 60 ...

Page 270: ...late Formerly 2001 88 Pump Housing Stub Trunnion Shaft Formerly 200236 Control Trunnion Shaft Formerly 200235 Needle Bearing Formerly 200237 Seal Washer Retaining Ring Spirol Pin Formerly 200234 Cap Screw Cylinder Block Kit Consists of nine pistons and a cylinder block not available separately plus the correct number of items 18 20 21 22 23 Slipper Retainer Washer Formerly200243 Spring Front Washe...

Page 271: ... Relief Valve Spring Relief Valve Cone Hex Plug O Ring Metering Plug O Ring Ball Spring Acceleration Valve Assembly O Ring Back Up Ring O Ring Motor Gasket Formerly200191 Motor End Cap Valve Plate Cylinder Block Kit Consists of nine pistons and a cylinder block not available separately plus the correct number of items 70 71 72 73 86 Retaining Ring Washer Spring Retainer Retaining Clip Acceleration...

Page 272: ...ormation 12169 Hydrogear Securing hydraulic valve hoses 3189 Hydrogear Sundstrand rebuilding service Piston Piston Bulletins 172 4175 174 5175 195 12176 Piston Piston Use of rust preventative on axles Piston Piston Differential bolt diameter change Piston Piston Motor snap ring failure 1975 and prior tractors S A 105124 217 2178 252 1l 79 273 5180 305 4181 Piston Piston Driven coupling installatio...

Page 273: ...RAULICS HYDRODYNAMICS HYDROSTATICS WORK POWER PRESSURE FLOW EFFICIENCY HYDRAULIC COMPONENTS RESERVOIR FILTER PUMP FUNCTION PUMPS BY TYPE VALVE FUNCTION VALVES BY NAME ACTUATOR ACTUATORS BY TYPE REVIEW SECTION 1 UNDERSTANDING CIRCUITS PROPERTIES OF LIQUIDS FORCE MAGNIFICATION BUILDING A BASIC CIRCUIT BUILDING A LIFT SYSTEM BUILDING A DRIVE SYSTEM THE REAL THING REVIEW SECTION 2 SPECIFICATIONS EATON...

Page 274: ...SOLVING STEP 1 ASK THE OPERATOR STEP 2 STUDY THE AVAILABLE INFORMATION STEP 3 INSPECT THE MACHINE STEP 4 OPERATE THE MACHINE TO VERIFY STEP 5 LIST THE POSSIBLE CAUSES STEP 6 TEST POSSIBLE CAUSES TEST EQUIPMENT INLET OUTLET HOSE PRESSURE GAUGE FLOW METER LOAD VALVE TEST EQUIPMENT NEEDS REVIEW SECTION 3 REVIEW SECTION ANSWERS REVIEW SECTION 1 REVIEW SECTION 2 REVIEW SECTION 3 ...

Page 275: ......

Page 276: ... has the potentialto start Avoid burns Do not touch the engine muffler or other components which may increaseintemperature during operation while the unitis running or shortly after it has been running Avoid fires and explosions Avoid spilling fuel and never smoke while working with any type of fuel or lubricant Wipe up any spilled fuel or oil immediately Never remove the fuel cap or add fuel when...

Page 277: ...Hydrostatics 6 Work 6 Power 7 Flow 7 Pressure 7 Efficiency 8 HYDRAULIC COMPONENTS Reservoir 8 Filter 8 Pump Function 9 Pumps ByType 9 Valve Function 11 Valves By 12 Actuator 14 Actuators By Type 14 REVIEW SECTION 1 16 PropertiesOfLiquids 17 ForceMagnification 17 BuildingA Basic Circuit 17 BuildingA LiftSystem 19 BuildingA DriveSystem 21 UNDERSTANDING CIRCUITS TheRealThing 21 1 Productivity Series ...

Page 278: ...uff Torq K61A 26 PROBLEM SOLVING Step 1 Ask The Operator 27 Step 2 Study The Available Information 27 Step 3 Inspect The Machine 28 Step 4 Operate the Machine to Verify 28 Step 5 List The Possible Causes 29 Step 6 Test Possible Causes 29 TEST EQUIPMENT Inlet Outlet Hose 30 PressureGauge 30 Flow Meter Load Valve 31 Test Equipment Needs 31 REVIEW SECTION 3 32 REVIEW SECTION ANSWERS 33 Productivity S...

Page 279: ...formation presented later Review sections throughout the book include questions which involve the key concepts presented If some questions are difficultto answer review the information again before proceeding Answers to the review questions are provided near the end of the book Why Should I Read This Book Hydraulics make up an important and expensive part of many of our products Mis diagnosing a p...

Page 280: ...to transmit power as compared to a mechanical system Hydrostatic transmissions provide for infinite variation of output speed A mechanical transmission is limited by the number of gear ratios it has around corners A mechanical system would require a complex belt chain or gear system to accomplish this Hydraulic hoses or lines can be routed The samefluid that transfers the energy also provides lubr...

Page 281: ...We Use Hydraulics Applications for hydraulics are diverse throughout industry With lawn and garden equipment the main uses are to 1 Propel the unit 2 Liftimplementsattachedtotheunit 1 1311 19 5 Productivity ...

Page 282: ...f liquids in motion Inall of our uses liquids referto oil Hydrodynamics refer to hydraulic systems which primarily use fluid flow to transfer energy This includes applications such as a water wheel or a torque converter Hydrostatics refer to hydraulic systems which primarily use fluid pressure to transfer energy This includes applications such as a hydraulic lift system or fluid powered transmissi...

Page 283: ...sureis measuredin pounds per square inch psi Pressure Force Area Ten pounds of force acting on one square inch provides 10 psi of pressure Increasing the load on a hydraulic system will increase the operating pressure of the system In a hydrostatic transmission higher pressures will be generated going uphill as compared to going downhill Flow Flow measures the transfer rate velocity of a liquid pa...

Page 284: ...yet very important component of any hydraulic system It serves as an expansion chamber and separates trapped air from the fluid Some systems use the gear case as a reservoir This allows dirt and metal filings to settle outof the fluid This type of reservoir allows for more fluid capacity which in turn assists in keeping the system properly cooled Reservoirs are generally vented and should prevent ...

Page 285: ... a range of angles variable displacement As the cylinder block rotates the piston either pulledby the swashplate or pushed by spring pressure extends out of the cylinder block and draws oil into the chamber On the opposite side the swashplate forces the piston in displacing oil from the base of the cylinder block Radial Ball Pistonpumps use several balls which travel through bores inside a rotor A...

Page 286: ... not require a crescent for sealing A Roller Bearing pump isa variation of the internal gear pump Instead of usingtwo gears rollers are placed between the teeth of the driven gear This also provides a Constant displacement of oil ExternalGear pumps usetwotightly meshed gears to produce a constant displacement of oil per revolution The input shaft drives one of the gears whichinturn drives the seco...

Page 287: ...first review these three functions of valves and then review some of the common types of valves you may encounter Pressure Controlvalves may be used to provide an upper pressure limit or to maintain a minimum pressurein a circuit For an example let slook at a lift system High pressureis generated when objects heavier than the system design are encountered or when a cylinder reaches the end of its ...

Page 288: ...th a transaxle a flow control valve may restrict flow through a passage completely during normal operation but when activated allow oil to pass through so the unit can be hand pushed Valves By Name Acceleration Valve An acceleration valve is a special flow control valve used in some hydrostatic transmissionsto smooth changesin speed or direction A common wayto do thisis by temporarily allowing som...

Page 289: ...uster Push Valve A push valveis a flow control valve usedto open a pump motor circuit Manually opening the circuit allows oil to bypass from one side of the circuitto the other or allows oil toescape back to the reservoir The push valve allows the unit to be moved without starting the engine Most but not all hydrostatic transmissions use a push valve I I I 3 4297 4111 3 4297 412 Relief Valve A rel...

Page 290: ... open center spool valve allows oil from the pump to pass through the valve when the spool is centered Actuator A hydraulic actuator is a device which converts hydraulic pressure and flow into mechanical energy Thetwo most common types of actuators are hydrostatic motors and hydraulic cylinders Actuators By Type A Motor is simply a pump used backwards It takes hydraulic pressure and flow from a pu...

Page 291: ...cylinder uses a large shaft called aram which replaces the piston and piston rod It can be serviced externally and eliminates the need for an atmospheric vent Dual Action Cylinder A dual action cylinder can be filled with oil on either side of the piston To extend the piston rod oil is forced into the bottom endof the cylinder and oil ahead of the piston is pushed out of the cylinder During retrac...

Page 292: ...uid pressure to transfer energy 4 Work is the applicationof a force through a 5 Power is the rate at which is done or energy is transferred 6 Flow is usually measured in per 7 An external gear pump is a displacement pump 8 List the three functions that a valve may perform 1 3 9 A hydraulic actuator converts hydraulic pressure and flow into 1O A cylinder can only be powered in one direction Product...

Page 293: ...10 poundsof force is applied to the pump 100pounds of forceis exerted on the cylinder If the amount of work putinto the system equals the amount of work out of the system I00 efficient the pump will travel 10times farther than the cylinder 3 4297 421 BuildingA Basic Circuit Let s put together a simple circuit using some basic hydraulic components We will start out with a simple pump and cylinder c...

Page 294: ...s seat As oil flows into the chamber the pressure beginsto increase As the handleis pushed downward the pressure inside the chamber increases and closes the check ball under the reservoir The second check ball now opens allowing the oil to flow into the chamber under the cylinder ram The force neededto extend the cylinder ram is dependent on the amount of weight on the ram A five pound weight requ...

Page 295: ...lace the hand pump with an external gear pump whichis capable of providing constant displacement and more flow By placing the pump in line we no longer need the check valvesto provide directional control The greater output of this pump will extend the cylinder much faster When the cylinder ram reaches the end of its stroke pressure will increase and open the relief valve If we replace the single a...

Page 296: ...hrough the spool valve and back to the reservoir When the pressureinthe cylinder reaches the setting of the pressure relief valve the valve opens and directs the oil flow backto the reservoir This happens when a high resistance is met such as the cylinder reaching the end of its stroke When the spool valve is offset in the opposite direction theoil flow through the valve and cylinder is reversed P...

Page 297: ...or Notice that there is nothing in this system that will allow the output speed to be changed Our hydrostatic drive systems use a variable displacement pump and a fixed displacement motor With variable output from the pump the spool valve is no longer needed to control the direction of oil flow The speed can also be changed with this variable output pump The Real Thing If we combine the drive syst...

Page 298: ...ost pressure 2 If both circuits below have the same amount of pressure applied to them which circuit A or B is capable of lifting more weight 3 Which valve A B or C in the circuit below is responsible for protecting the system from high pressure Productivity Series 22 ...

Page 299: ... the reservoir provides for filtration of incoming oil This unit must be coupled to a final drive to provide power to the drive wheels Eaton Model11 The Eaton 11is similar to the model7 but is considerably larger and uses an auxiliary charge pump The pump displacesa maximum of 1 15 cu in 18 85cc per revolution and the motor has a 2 09 cu in 34 25 cc displacement per revolution The charge pump supp...

Page 300: ...o the axle Hydro Gear 316 0500 This is a typical hydrostatic transaxle used in a lawn tractor It is completely self contained and has its own differential This transaxle utilizes a variable axial piston pump with a maximum displacementof 0 61 cu in 10 cc per revolution The motoris also an axial piston design with a fixed displacement of 1 28 cu in 21 cc per revolution Hydro Gear316 0750 This hydro...

Page 301: ...l displacement pump is used to drive the wheel motor The pump must complete several revolutionsto displace enough oil to drive the wheel motor through one revolution This provides a speed reduction similar to using reduction gearsin a mechanical transmission Sundstrand Series15 The Sundstrand Series 15 uses an axial piston variable pump with a fixed displacement axial piston motor The maximum pump...

Page 302: ...tained and has its own differential It utilizes a variable axial piston pump and with a fixed displacement axial piston motor An internal spring assists in returning the control arm to neutral A dampening pistonis used on the motion control input arm to smooth directionalchanges 26 ...

Page 303: ...ccurred Answers to these questions should be recorded on the work order Step 2 Study The Available Information Review the technical information which applies to the hydraulic system you are working with Flow diagrams will show which types of components are involved in the system Can the problem be related to a particular circuit or partof a circuit Does the problem seem to be pressure related Does...

Page 304: ...t secure Is there debris around the hydraulic components Are thehoses lineskinked Are there any signs of leakage Inspect the drive for the system Does the input drive line look normal Are there signsof slippage in the system Does everything seem secure Are the drive keys in place Can you push the unit without activating the push valve Inspect the output drive Step 4 Operate the Machine to Verify I...

Page 305: ...uses to verify your conclusions Start with the items on your list which are the easiest to check If it is not be possible to pinpoint the problem to one component an internal inspection will be necessary Possible Causes Charge pump failing low output Internal cylinder leakage Spool valve problem Hose kinked Relief valve problem Spoolvalve linkage Check The Easy Things First Hose kinkedeasy Spool v...

Page 306: ...es are used to connect your test equipment into the system you are testing The hoses should be rated higher than any pressure that may be reached during testing They should also be long enough to allow for easy readingof the test equipment Adapter fittings may be needed to attach to different systems Pressure Gauge As you might expect pressure gauges are used to measure the pressures experienced d...

Page 307: ... many different systems simply by using adapter fittings Your test equipment should be capable of handling pressures greater than the pressure generated by the largest system you will need to test A liquid filledgauge capable of1000psi 70 3 kg sq cm will be sufficient for testing hydraulic systems on TORO Wheel Horse riding products Some systems used on TORO ProLine equipment require a flow meter ...

Page 308: ...n overheated hydraulic system is A Burntsmellingfluid B Oil loss in the system C Lossof power as the system warms D Air bubbles in the reservoir E Blackcoloredoil 4 When testing the possible causes of a hydraulic system problem always test the possibilities first 5 When using a load valve during testing as flow is restricted a higher is simulated 6 The test equipment used inyour shop should be cap...

Page 309: ... equal to pressure times the area on which it is acting The pressureis the samein both circuits The cylinder in circuit A is larger than the cylinder in circuit The same pressure times a larger area will generate the most force 3 Valve C Valve A is a check valve which keeps oils from returning to the reservoir during pumping Valve B keeps the oil trapped under the lift cylinder Valve C is used as ...

Page 310: ...ort to make the informationin this manual complete and correct We are hopeful that you will find this manual a valuable addition to your service shop If you have any questions or comments regarding this manual please contact us at the following address The ToroCompany Consumer Service Training Department 8111 Lyndale Ave S Bloomington MN 55420 The Toro Company reserves the right to change product ...

Page 311: ...O SERVICE NOTES DISASSEMBLY REASSEMBLY VALVE DESCRIPTION VICTOR OVERHAUL KIT CONTENTS VICTOR VICTOR 110068 111066 CONTROL VICTOR 110492 CONTROL VALVE OVERHAUL PROCEDURE VICTOR SERVICE NOTES DISASSEMBLY REASSEMBLY SINGLE SPOOL VICTOR DISASSEMBLY TWO SPOOL VICTOR ASSEMBLY TWO SPOOL VICTOR LIFT CYLINDER SERVICE GENERAL INFORMATION CYLINDER DESCRIPTION O RING GASKET KIT CONTENTS OVERHAUL PROCEDURE SER...

Page 312: ...HYDRAULIC LIFT VALVE CYLINDER REPAIR MANUAL Printed in U S A 0984 PART NO 810242R3 ...

Page 313: ...agesofservice and repair Even asmallamountof dirt orcontamination canseverely damage components Always usecleansolventwhencleaningparts If con tamination of hydraulic system has occurred or is suspected be sure to cleanentire system Clean l i f t cylinder valve all hoses and lines Transmission and transaxle must be cleaned to insure all contaminants are removed CONTROL VALVE SERVICE 1 GENERALINFOR...

Page 314: ...nufactured is stamped on the flat side of the outlet cover as shown in Figures 1 2 Oneor two lines ofinformationmay be on the cover which are decodedas follows Example on all valves 0948 1 9 Example on some valves SR115 4 0 Manufacturer s Control numbers Month Built Year Built 1 January 12 December 9 1979 0 1980 1 1981 etc VALVEDESCRIPTION OMCO The hydraulic control valves are made upof one or two...

Page 315: ...ed aroundbolt holes between sections 3 Section O rings may be greased to hold them in place lubricate spool valve O rings and spool valve withoil when reassembling Disassembly Reassembly 1 Remove the push nut from the valve handle pin and remove the valve handle orhandles ASSEMBLINGA DOUBLEVALVE FIG 4 Remove Valve Handle s Double Valve Shown 2 Remove the parts shown in Fig 5A or 5B as applicable S...

Page 316: ...he shoulder passes through the center of the specialwasher or the spool valve will operate in only one direction e The float detent on valves so equipped Fig 5B is adjusted using the setscrew on the bottomof the valve Properly adjusted the spool valve w i l l lock into the float posi tion when engaged yet release easily when light pressure is appliedto the handle VALVEDESCRIPTION VICTOR The hydrau...

Page 317: ... 12 2 13 2 14 1 15 1 16 2 17 1 O Ring LoadCheckPlug O Ring Spool Screw With Lockwasher Spacer Screw Steel Ball Detent Washer Spacer Spool w o Detent Return Spring Spool w o Detent Return Spring Spool With Detent Detent Spacer Screw Spacer Spool With Detent Spring Load Check Valve Spring Detent Spring Relief Valve Ball Retainer Gasket Relief Valve Steel Ball Relief Valve Except for the valve handle...

Page 318: ...nd washer from valve Fig 16 SPOOL BORE SPOOL LINK a COTTER PIN CLEVIS PIN a COTTER PIN FIG 16 Spool Without Detent 2 Remove cotter pinandlinkfrom valvebodyand handle Pull handle and spool out of valve Re 5 move cotter pin clevis pin and handle from spool Remove O Rings from valve body 3 Remove two detent plugs springs and balls from detent end cap Fig 17 Remove two detent end cap screws and end ca...

Page 319: ...ef valve side Fig 16 Push spool into bore only far enough to expose handle side 0 Ring groove in valve body Coat 0 Ring withlithium grease andinstall in groove of valve body Check that 0 Ring is properly seated in groove Push spool over O Ring only far enough so that other end of spool exposes 0 Ring groove in valve body Coat 0 Ring withlithium grease andinstall in groove of valve body Check that ...

Page 320: ...Guide Bushing 5 1 O ring Guide Bushing O D 6 1 Rectangular SectionSeal Piston 7 1 O ring Piston 8 1 Retaining Ring No other repair parts are available The lift cylinder must be replaced if theservice kit fails to solvethe problem OVERHAUL PROCEDURE Service Notes Guide Bushing O ring 1 Use a clean dirt freework surface and clean solvent to prevent system contamination 2 lubricate all internal parts...

Page 321: ...e new O rings gaskets and sealscon tained in theservice kit Onegasket should be on each side of the piston O ring Fig 24 cylinders Use masking tape as indicated in Fig 24 26 to protect the O rings from damage during assembly Use extreme care when installing parts into the cylinder Be sure the piston and bushing O rings arenot cuton the grooves inside the cylinder Carefully align the parts before a...

Page 322: ...Horse Products Inc reserves the right to Product Information and specifications are shown herein as of the change product specifications designs andstandard equipment without notice and without incurring obligation WHEEL HOME ...

Page 323: ...O SERVICE NOTES DISASSEMBLY REASSEMBLY VALVE DESCRIPTION VICTOR OVERHAUL KIT CONTENTS VICTOR VICTOR 110068 111066 CONTROL VICTOR 110492 CONTROL VALVE OVERHAUL PROCEDURE VICTOR SERVICE NOTES DISASSEMBLY REASSEMBLY SINGLE SPOOL VICTOR DISASSEMBLY TWO SPOOL VICTOR ASSEMBLY TWO SPOOL VICTOR LIFT CYLINDER SERVICE GENERAL INFORMATION CYLINDER DESCRIPTION O RING GASKET KIT CONTENTS OVERHAUL PROCEDURE SER...

Page 324: ...HYDRAULIC LIFT VALVE CYLINDER REPAIR MANUAL Printed in U S A 0984 PART NO 810242R3 ...

Page 325: ...agesofservice and repair Even asmallamountof dirt orcontamination canseverely damage components Always usecleansolventwhencleaningparts If con tamination of hydraulic system has occurred or is suspected be sure to cleanentire system Clean l i f t cylinder valve all hoses and lines Transmission and transaxle must be cleaned to insure all contaminants are removed CONTROL VALVE SERVICE 1 GENERALINFOR...

Page 326: ...nufactured is stamped on the flat side of the outlet cover as shown in Figures 1 2 Oneor two lines ofinformationmay be on the cover which are decodedas follows Example on all valves 0948 1 9 Example on some valves SR115 4 0 Manufacturer s Control numbers Month Built Year Built 1 January 12 December 9 1979 0 1980 1 1981 etc VALVEDESCRIPTION OMCO The hydraulic control valves are made upof one or two...

Page 327: ...ed aroundbolt holes between sections 3 Section O rings may be greased to hold them in place lubricate spool valve O rings and spool valve withoil when reassembling Disassembly Reassembly 1 Remove the push nut from the valve handle pin and remove the valve handle orhandles ASSEMBLINGA DOUBLEVALVE FIG 4 Remove Valve Handle s Double Valve Shown 2 Remove the parts shown in Fig 5A or 5B as applicable S...

Page 328: ...he shoulder passes through the center of the specialwasher or the spool valve will operate in only one direction e The float detent on valves so equipped Fig 5B is adjusted using the setscrew on the bottomof the valve Properly adjusted the spool valve w i l l lock into the float posi tion when engaged yet release easily when light pressure is appliedto the handle VALVEDESCRIPTION VICTOR The hydrau...

Page 329: ... 12 2 13 2 14 1 15 1 16 2 17 1 O Ring LoadCheckPlug O Ring Spool Screw With Lockwasher Spacer Screw Steel Ball Detent Washer Spacer Spool w o Detent Return Spring Spool w o Detent Return Spring Spool With Detent Detent Spacer Screw Spacer Spool With Detent Spring Load Check Valve Spring Detent Spring Relief Valve Ball Retainer Gasket Relief Valve Steel Ball Relief Valve Except for the valve handle...

Page 330: ...nd washer from valve Fig 16 SPOOL BORE SPOOL LINK a COTTER PIN CLEVIS PIN a COTTER PIN FIG 16 Spool Without Detent 2 Remove cotter pinandlinkfrom valvebodyand handle Pull handle and spool out of valve Re 5 move cotter pin clevis pin and handle from spool Remove O Rings from valve body 3 Remove two detent plugs springs and balls from detent end cap Fig 17 Remove two detent end cap screws and end ca...

Page 331: ...ef valve side Fig 16 Push spool into bore only far enough to expose handle side 0 Ring groove in valve body Coat 0 Ring withlithium grease andinstall in groove of valve body Check that 0 Ring is properly seated in groove Push spool over O Ring only far enough so that other end of spool exposes 0 Ring groove in valve body Coat 0 Ring withlithium grease andinstall in groove of valve body Check that ...

Page 332: ...Guide Bushing 5 1 O ring Guide Bushing O D 6 1 Rectangular SectionSeal Piston 7 1 O ring Piston 8 1 Retaining Ring No other repair parts are available The lift cylinder must be replaced if theservice kit fails to solvethe problem OVERHAUL PROCEDURE Service Notes Guide Bushing O ring 1 Use a clean dirt freework surface and clean solvent to prevent system contamination 2 lubricate all internal parts...

Page 333: ...e new O rings gaskets and sealscon tained in theservice kit Onegasket should be on each side of the piston O ring Fig 24 cylinders Use masking tape as indicated in Fig 24 26 to protect the O rings from damage during assembly Use extreme care when installing parts into the cylinder Be sure the piston and bushing O rings arenot cuton the grooves inside the cylinder Carefully align the parts before a...

Page 334: ...Horse Products Inc reserves the right to Product Information and specifications are shown herein as of the change product specifications designs andstandard equipment without notice and without incurring obligation WHEEL HOME ...