Case Skid Steer Loader Service Manual Pgs 988-1192
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools
PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.
84423866 25/07/2011 EN
SERVICE MANUAL ENGINE AND PTO IN
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
84423866 25/07/2011
B
Contents ENGINE AND PTO IN - B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
84423866 25/07/2011
B
ENGINE AND PTO IN - B ENGINE - 10.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
84423866 25/07/2011
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Contents ENGINE AND PTO IN - B ENGINE - 10.A
SERVICE ENGINE Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SR130, SR150, SR175, SV185
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SR130, SR150, SR175, SV185
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
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ENGINE AND PTO IN - ENGINE
ENGINE - Remove SR130, SR150, SR175, SV185
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A).
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ENGINE AND PTO IN - ENGINE
1.
2.
3.
Remove the hood strut (1) from hood
931001682
1
931002025
2
931002026
3
Remove hood mounting hardware (2) from left and right hand side
Remove the hood (3).
4.
Remove the rear access door refer to Engine hood - Remove (E.20.A).
5.
Drain the engine oil.
6.
Remove the radiator refer to Radiator - Remove (B.50.A).
7.
Remove the oil cooler refer to Oil cooler - Remove (A.10.A).
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ENGINE AND PTO IN - ENGINE
8.
9.
10.
11.
Remove the four mounting bolts (4) and slide the fan off the hub.
931002027
4
931002028
5
931002029
6
931002030
7
Remove the five mounting bolts (5) retaining the muffler inlet pipe mounting flange to the turbocharger and remove muffler.
Remove the two retaining bolts (6) from the muffler support.
Disconnect air restriction sensor (7).
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ENGINE AND PTO IN - ENGINE
12.
13.
14.
15.
Loosen the hose clamps on the intake tube at both ends, remove the intake tube (8), cover turbocharger inlet to avoid entry of debris.
931002031
8
931002032
9
Remove air cleaner housing (9).
Loosen hose clamp and remove upper radiator hose (10) from engine.
931002033
10
931002034
11
Disconnect the glow plug connection (11). Remove wire clamp (12).
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ENGINE AND PTO IN - ENGINE
16.
17.
18.
19.
Disconnect the starter connections (13).
931002035
12
931002036
13
931002037
14
931002038
15
Disconnect the alternator connection (14).
Disconnect temperature sender wire (15).
Disconnect oil pressure sender wire (16) and wire clamp (17).
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ENGINE AND PTO IN - ENGINE
20.
21.
22.
Disconnect throttle cable by removing the nut (A)and bolt (B) from the throttle body. Remove cable support clamp (C) by loosening the two hex head bolts (D).
931002039
16
931002040
17
931002042
18
Disconnect wire harness (18) and clamps (19) from the top of the flywheel housing.
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
Place a suitable container under lines to prevent spillage and remove the fuel supply line (20). 84423866 25/07/2011
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ENGINE AND PTO IN - ENGINE
23.
24.
25.
Remove the fuel return line (21).
931002041
19
931002043
20
931002044
21
931002045
22
Disconnect the spade connector (E)from the back side of the fuel shut off solenoid.
Place a suitable container under the remote engine oil filter lines. Label and disconnect oil filter lines (22).
NOTE: Cap the ends to avoid entry of debris.
26.
Disconnect the ground from the engine (23) to the battery quick disconnect.
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ENGINE AND PTO IN - ENGINE
27.
28.
29.
30.
Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate
931002046
23
931002050
24
931002047
25
931002048
26
Remove engine oil pan drain hose clamp (F).
Remove the front engine mounts (25).
Remove the rear engine mount (26).
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ENGINE AND PTO IN - ENGINE
31.
32.
33.
Remove the four mounting bolts (27) from the fixed hood, remove hood.
931002049
27
931002051
28
931002052
29
931002053
30
Place a suitable support beam across the skid steer frame. Tie a suitable strap around the pump and secure to the support beam, as shown.
DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A
Attach proper lifting straps to the eye hooks (28) provided on the engine.
34.
Use a suitable hoist to carefully lift the engine slightly rearward to separate from the hydraulic pumps. Once free, lift the engine and remove from the rear of chassis.
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ENGINE AND PTO IN - ENGINE
ENGINE - Remove SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A). Prior operation: Radiator - Remove (B.50.A)
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ENGINE AND PTO IN - ENGINE
1.
2.
Remove the hood struts (1) from each side by gently prying the retaining clip (2) just enough to release the strut.
1
931002025
2
931002026
3
931001896
4
Remove hood mounting hardware (1) from left-hand and right-hand side of the hood.
3.
Remove the hood (1).
4.
Remove the rear access door refer to Engine hood - Remove (E.20.A).
5.
Remove the oil cooler refer to Oil cooler - Remove (A.10.A).
6.
931001887
Remove the three mounting bolts (1) retaining the muffler inlet pipe mounting flange to the turbocharger, cover turbocharger inlet the avoid entry of debris.
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ENGINE AND PTO IN - ENGINE
7.
8.
9.
10.
Remove the four retaining bolts (1) from the muffler support.
931001895
5
931002030
6
931001898
7
931001899
8
Disconnect air restriction sensor (1).
Loosen the hose clamps on the intake tube at both ends, remove the air cleaner to turbo charger tube (1).
Remove the engine cover (1).
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ENGINE AND PTO IN - ENGINE
11.
Remove air cleaner housing (1) by removing the three bolts (2).
931001900
12.
13.
14.
9
Loosen hose clamp (1) and remove upper radiator hose (2) from engine.
931001903
10
931001908
11
931001909
12
Disconnect the alternator electrical connections (1).
Disconnect the starter electrical connections (1).
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ENGINE AND PTO IN - ENGINE
15.
16.
17.
Disconnect ground connection (1) below the starter (2).
931001910
13
931001911
14
931002113
15
Unplug wire harness connection (1).
Disconnect low pressure line (1) from the Air-conditioning compressor (2).
NOTE: Place a suitable container under the machine to catch any lost fuel.
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ENGINE AND PTO IN - ENGINE
18.
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING
931001917
16
931001919
17
931001922
18
Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
Remove the fuel return line (1). 19.
20.
Remove the fuel supply line (1).
Remove the throttle cable (1).
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ENGINE AND PTO IN - ENGINE
21.
22.
23.
24.
Place a suitable container under the remote engine oil filter lines (1). Label and disconnect oil filter lines.
931001923
19
931002046
20
931001925
21
931001926
22
Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate
Disconnect fuel pump electrical connection (1).
Disconnect harness (1) from connector (2).
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ENGINE AND PTO IN - ENGINE
25.
26.
27.
28.
Place a suitable support beam (1) across the skid steer frame. Tie a suitable strap (2) around the pump (3) and secure to the support beam, as shown.
931001929
23
931001928
24
931001936
25
931001944
26
Remove the two pump mounting bolts (1).
Disengage pump assembly (1) from engine housing (2).
DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A
Attach proper lifting straps (1) to support the engine (2).
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ENGINE AND PTO IN - ENGINE
29.
30.
31.
32.
Remove the front and rear engine mounts (1).
931001933
27
931001938
28
931002050
29
931001943
30
Raise the engine slightly as shown.
Remove engine oil drain hose clamp (1).
Remove heater hose clamp (1).
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ENGINE AND PTO IN - ENGINE
33.
Remove upper heater hose (1).
NOTE: Use a suitable device to catch any coolant not drained previously.
34.
35.
931002114
31
931001940
32
931001946
33
Remove lower heater hose (1).
WARNING Heavy object! ALWAYS use adequate lifting equipment (heavy-duty hoist, loader, or forklift) to lift the component. Failure to comply could result in death or serious injury. W0101A
Remove engine (1) from the chassis.
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ENGINE AND PTO IN - ENGINE
ENGINE - Install SR130, SR150, SR175, SV185
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
Attach proper lifting straps to the eye hooks (1) provided on the front right and rear left of the engine.
931002052
1
931002053
2
931002046
3
Using a suitable hoist carefully lower engine into engine compartment on the skid steer.
3.
Slowly orient the hydraulic pump coupler to the adapter on the engine ensuring the attachment of engine plate to flywheel housing.
4.
Attach engine to hydraulic pump mounting plate using the twelve mounting bolts (2).
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ENGINE AND PTO IN - ENGINE
5.
6.
7.
8.
Remove support brace and straps from hydraulic pump.
931002051
4
931002047
5
931002048
6
931002049
7
Install front engine mounting bolts (3).
Install rear engine mounting bolt (4).
Install Fixed hood and secure with hardware (5).
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ENGINE AND PTO IN - ENGINE
9.
10.
11.
12.
Install engine oil pan drain hose into clamp (6).
931002050
8
931002045
9
Connect ground from the quick battery disconnect to the engine (7).
Connect remote engine oil filter lines (8).
931002044
10
931002043
11
Connect the spade connector to the back of the fuel shut off solenoid (9).
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ENGINE AND PTO IN - ENGINE
13.
14.
15.
16.
Connect the fuel return line (10).
931002041
12
931002042
13
931002040
14
931002039
15
Connect the fuel supply line (11).
Connect the wire harness (12) and clamps (13) to the top of the flywheel housing..
Connect throttle cable by installing the nut (A)and bolt (B) to the throttle body. Install cable support clamp (C) and tighten the two hex head bolts (D).
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ENGINE AND PTO IN - ENGINE
17.
18.
19.
20.
Connect oil pressure sender wire (14) and support (15).
931002038
16
931002037
17
931002036
18
931002035
19
Connect temperature sensor wire (16).
Connect alternator connection (17).
Connect starter connections (18).
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ENGINE AND PTO IN - ENGINE
21.
22.
23.
24.
Connect glow plug connection (19) and wire clamp (20).
931002034
20
931002033
21
931002032
22
931002031
23
Install upper radiator hose (21) to engine and tighten hose clamp.
Install air cleaner housing to bracket, secure with mounting bolts (22).
Install air cleaner to turbo hose (23) and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE
25.
26.
27.
28.
Connect air restriction sensor (24).
931002030
24
931002028
25
931002029
26
931002027
27
Install muffler inlet pipe mounting flange to turbocharger and secure with the five mounting bolts (25).
Install the two retaining bolts (26) to the muffler support.
Place fan on hub and secure with the four retaining bolts (A).
29.
Install oil cooler refer to Oil cooler - Install (A.10.A).
30.
Install radiator refer to Radiator - Install (B.50.A).
31.
Add engine oil.
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ENGINE AND PTO IN - ENGINE
32.
Fill hydraulic oil reservoir refer to Reservoir - Filling (A.10.A).
33.
Fill coolant refer to Radiator - Filling (B.50.A).
34.
Lift engine hood into place on the top of the skid steer.
35.
36.
931002026
28
931002025
29
931001682
30
Install the left and right hand side hood mounting bolts (27).
Connect the hood support strut (B) to the left hand side of hood.
37.
Install rear access door refer to Engine hood - Install (E.20.A).
38.
Lower cab refer to Tilt system - Lower (E.34.A).
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ENGINE AND PTO IN - ENGINE
ENGINE - Install SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
3.
Attach proper lifting straps to the eye hooks provided on the front and rear of the engine, as shown.
931001946
1
931001944
2
931001936
3
Using a suitable hoist carefully lower engine into engine compartment on the skid steer.
Carefully orient hydraulic pump coupler to adapter on the engine ensuring attachment of engine plate to flywheel housing.
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ENGINE AND PTO IN - ENGINE
4.
5.
6.
7.
Install pump mounting bolts and washers (1) into pump housing.
931001928
4
931001933
5
931002047
6
931001929
7
Install the two rear engine mounting bolts and bushings (2).
Install the two front engine mounting bolts and bushings (3).
Verify pump mounting bolts are secure and carefully remove support brace (4)and straps (5) from pump.
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ENGINE AND PTO IN - ENGINE
8.
9.
10.
11.
Connect the lower heater hose (6).
931001940
8
931002114
9
Connect the upper heater hose (7).
Attach heater hose support clamp (8).
931001943
10
931002050
11
Attach engine oil pan drain hose support clamp (9).
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ENGINE AND PTO IN - ENGINE
12.
13.
14.
15.
Connect the wiring harness connection (10).
931001926
12
931001925
13
931001923
14
931001922
15
Connect the fuel pump wire connection (11).
Connect the two remote oil filter lines (12) and (13) as previously labeled.
Connect throttle cable by installing the nut (A) and bolt (B) to the throttle body. Install cable support clamp and tighten the two hex head bolts (C).
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ENGINE AND PTO IN - ENGINE
16.
17.
18.
19.
Connect fuel supply line (14).
931001919
16
931001917
17
931002113
18
931001911
19
Connect fuel return line (15).
Connect low pressure line to the air condition compressor (16).
Connect wire harness connection (17) located on left hand side above motor mount.
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ENGINE AND PTO IN - ENGINE
20.
21.
22.
23.
Connect the ground to engine from battery quick disconnect (18) and cab ground (19).
931001910
20
931001909
21
931001908
22
931001903
23
Connect the two starter connections (D) and (E).
Connect the two alternator connections (F) and (G).
Install upper radiator hose (20) to engine and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE
24.
25.
26.
27.
Install the three mounting bolts (21) that secure air cleaner housing and bracket to frame.
931001900
24
931001899
25
931001898
26
931001897
27
Install the fixed hood and secure with hardware (22).
Connect air cleaner to turbo hose (23).
Connect air restriction sensors electrical connection (24).
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ENGINE AND PTO IN - ENGINE
28.
29.
30.
31.
Install the four mounting bolts from the muffler brackets (25).
931001895
28
931001896
29
931001894
30
931001887
31
Install the three retaining bolts (26) to the exhaust manifold mounting flange .
Attach lifting straps through the engine hood and hoist in mounting location.
Install left and right hand side hood mounting hardware (27).
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ENGINE AND PTO IN - ENGINE
32.
33.
34.
35.
Connect left and right hand side hood struts (28).
931001887
32
931001893
33
931001890
34
931001889
35
Connect condenser fan electrical connection (29).
Connect top and bottom air condition condenser lines (30).
Install air condition refrigerant.
Next operation: Oil cooler - Install (A.10.A). Next operation: Radiator - Install (B.50.A). 84423866 25/07/2011
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ENGINE AND PTO IN - ENGINE
Next operation: Reservoir - Filling (A.10.A). Next operation: Radiator - Filling (B.50.A). Next operation: Tilt system - Lower (E.34.A).
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Index ENGINE AND PTO IN - B ENGINE - 10.A ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SR130, SR150, SR175, SV185
ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SR130, SR150, SR175, SV185
ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
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ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A
TECHNICAL DATA Sensing system General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Throttle command Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system - General specification Resistance Fuel Bar Conversion Resistance Fuel Bar Conversion for Large Machines Resistance Low (in Ω) < 32 33 68 108 155 188 211 243
Resistance High (in Ω) 32 67 107 154 187 210 242 > 243
Bars 8 7 6 5 4 3 2 1
Resistance Fuel Bar Conversion for Medium Machines Resistance Low (in Ω) < 32 33 48 88 132 155 201 231
Resistance High (in Ω) 32 47 87 131 154 200 230 > 231
Bars 8 7 6 5 4 3 2 1
Resistance Fuel Bar Conversion for Small Machines Resistance Low (in Ω) 86 80 73 66 55 38 16 0
Resistance High (in Ω) > 86 85 79 72 65 54 37 15
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Bars 8 7 6 5 4 3 2 1
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Throttle command - Adjust 1.
2.
3.
Start the machine. Press and Hold Auxiliary Over Ride Button (1) for 2 seconds. Release button, and press to toggle (2) to next display setting. Continue to press and release button until RPM’s are displayed
931007504
1
93111552
2
93111549
3
Adjust the clevis (1) on the end of the foot pedal, so that with the first 5 degrees of handle movement the pedal starts to move. If the pedal does not move with the throttle handle, turn the clevis in to shorten the cable.
Loosen the jam nut (1), turn the stop bolt (2) IN several turns.
NOTE: Make sure the plunger is through the L-Bracket when the jam nut is tight. Plunger must move freely through L-bracket . Do not pinch the L-Bracket between plunger and washer. 4.
Place engine throttle in low idle position to adjust cable length on the engine. Turn the plunger thumb screw (1) in until cable (2) is fairly tight. If cable is too tight, the engine will not return to low idle. Idle should be approximately 1075 RPM +/- 75 RPM.
93111551
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4
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
5.
6.
Move hand throttle (1) to full position. Full throttle should be approximately 2675 RPM +/- 75 RPM.
93111550
5
93111549
6
Turn stop bolt (1) OUT until is contacts the pedal. Tighten the jam nut (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel tank - Remove WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
Disconnect the fuel sender connector (1).
931002098B
1
931002098B
2
Label and disconnect fuel supply line (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
3.
4.
5.
Remove left hand side fuel tank bracket (3).
931002099B
3
931002100B
4
Remove right hand side fuel tank bracket (4).
Drain fuel from the tank using the drain plug located at the bottom of the tank.
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
6.
Remove fuel tank.
931002102B
Next operation: Fuel tank - Install (B.20.A)
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5
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel tank - Install WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
Prior operation: Fuel tank - Remove (B.20.A) 1.
2.
Position fuel tank into correct location on skid steer.
931002102B
1
931002099B
2
Install left hand side fuel tank bracket (1).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
3.
4.
5.
6.
Install right hand side fuel tank bracket (2).
931002100B
3
931002098B
4
931002098B
5
Connect fuel supply line (3).
Connect fuel sender (4).
Install engine refer to ENGINE - Install (B.10.A).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system Level sensor - Remove Fuel Level Sender 1.
2.
3.
Locate and open rear engine hood (1).
93111006AB
1
931002032
2
931002098
3
Remove hardware (1) from air filter housing (2).
Disconnect connector X-14 (1) from the fuel level sender B-001 (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
4.
5.
6.
Label and disconnect the fuel lines (1).
931002098
4
931002098
5
931002098
6
Remove hardware (1) and fuel level sender retainer (2).
Remove fuel level sender B-001 (1) from fuel tank.
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system Level sensor - Install Fuel Level Sender 1.
2.
3.
4.
Insert fuel level sender B-001 (1) into the fuel tank.
93111533
1
93111534
2
931002098
3
931002098
4
Place the fuel level sender retainer (1), and hardware (2) onto fuel tank. Tighten hardware.
Reconnect the fuel lines (1).
Reconnect connector X-14 (1) to the fuel level sender B-001 (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
5.
6.
Install air filter housing (1) and bolts (2). Tighten the bolts.
931002032
5
93111006AB
6
Close rear engine hood (1).
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Index ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sensing system - General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sensing system Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Throttle command - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A
SERVICE Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Sensing system Air cleaner restriction - Remove 1.
2.
3.
4.
Locate and open rear engine hood (1) and service door (2).
93107449A1
1
931002032
2
931002030
3
931002030
4
Remove hardware (1) from air filter housing (2).
Remove hose clamp (1) from air cleaner assembly (2).
Remove clip (1) securing connector X-508. Disconnect connector X-508 from the air filter restriction switch B-016 (2).
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
5.
Unscrew the air filter restriction switch B-016 (1) by hand from air cleaner assembly (2).
931002030
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5
ENGINE AND PTO IN - AIR INTAKE SYSTEM
Sensing system Air cleaner restriction - Install 1.
2.
3.
4.
Install the air filter restriction switch (1) into the air cleaner assembly.
931002030
1
931002030
2
931002030
3
931002032
4
Connect the connector (1) to the air filter switch, and insert clip (2).
Place hose clamp (1) over hose and connect to air cleaner assembly (2). Tighten the hose clamp.
Insert hardware (1), and attach air cleaner assembly (2) to mount.
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Index ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A Sensing system Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A
SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Remove WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A
Prior operation: Radiator - Drain fluid (B.50.A). 1.
2.
3.
Disconnect the radiator over-flow hose, (1), at the radiator and elevate above the overflow reservoir allowing fluid to drain into over-flow. Hose can be draped anywhere it is save from damage.
931001645
1
931001648
2
931001650
3
Loosen the hose clamp and remove the upper radiator hose from the radiator (2).
Loosen the top mounting bolts from both left hand side and right hand side of radiator (3).
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
4.
5.
6.
Tilt the top of the radiator out, as shown.
931001653
4
931002071
5
931002060
6
931002061
7
Loosen the hose clamp and disconnect lower radiator hose (4).
Remove the two radiator support clips (5) from the support pins on the right hand side of bracket. Push the support pins out.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
7.
8.
Remove left hand side support hardware (6) from the bottom of the bracket.
931002062
8
931001654
9
Remove radiator along with left hand side bracket.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Install 1.
2.
3.
Slide radiator back in right hand side mounting bracket (1).
931001654
1
931002062
2
931002071
3
Install left hand side bracket support hardware (2).
Tilt radiator out and connect lower radiator hose (3) and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
4.
5.
6.
Push right hand side radiator support pins through bracket and install retaining clips (4).
931002060
4
931002061
5
931001653
6
931001650
7
Tilt radiator in and align top brackets.
Tighten top mounting bolts (5) on both left and right hand side.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
7.
8.
9.
Connect the upper radiator hose (6) to the radiator and tighten hose clamp.
931001648
8
931001645
9
Connect over flow hose (7).
After the radiator has been installed refer to the following procedure for filling the radiator. Radiator Filling (B.50.A).
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Drain fluid WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A
1.
If engine is HOT do not drain cooling system. Allow the system to cool before draining the radiator.
2.
Open the rear access door.
3.
Drain the engine coolant system by loosening the drain valve (1), and drain the coolant into a suitable container. When the radiator is empty, tighten the drain valve
931001644
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1
ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Filling CAUTION Burn hazard! Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir. Failure to comply could result in minor or moderate injury. C0031A
1.
2.
3.
Open the rear access door and remove the radiator cap (1) after the engine has cooled.
931001652
1
931001645
2
Fill the radiator with a 50% mixture of ethylene glycol engine coolant and 50% water mixture. The coolant level must be to the top of the radiator fill neck, just below the overflow tube (1). Install cap loosely (2).
Start and run the engine until it reaches operating temperature. Stop the engine and check the level of the coolant in the recovery bottle (2). Fill the recovery bottle with a 50% mixture of ethylene glycol engine coolant and 50% water mixture to the full level marked on the bottle. Once level is good tighten cap.
NOTICE: Do not remove the radiator cap from the radiator while the engine is HOT.
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Index ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE AND PTO IN - B STARTING SYSTEM - 80.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B STARTING SYSTEM - 80.A
FUNCTIONAL DATA Cold start aid Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC Start control Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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ENGINE AND PTO IN - STARTING SYSTEM
Cold start aid - Overview Engine preheat During cold starts, diesel engine preheating is completed by the use of glow plugs. Engines use glow-plugs in each combustion chamber to increase the temperature of the cylinder. Diesel engines rely solely on compression to raise the temperature of the air to a point where the diesel will combust spontaneously when introduced to the hot high pressure air. At normal temperature, the high pressure and spray pattern of the diesel ensures a controlled, complete burn. The piston rises, compressing the air in the cylinder; this causes the air's temperature to rise. By the time the piston reaches the top of its travel path, the temperature in the cylinder is very high. The fuel mist is then sprayed into the cylinder; it instantly combusts, forcing the piston downwards, thus generating power.
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ENGINE AND PTO IN - STARTING SYSTEM
Start control - Testing Ignition Switch NOTE: Wiring Wiring Wiring
Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 14 (A.30.A)
Test Point N° 1 Condition Use Fuse and relay box - Testing Main Power Relay Control (A.30.A) to check MAIN POWER RELAY. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-316 pin A. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-C23 pin 21. 4 Condition Disconnect connector X-316 from the IGNITION BACKFEED DIODE V-007 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 2 and connector X-C23 pins 9 and 11. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 1 and connector X-C23 pin 3. 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 6 and connector X-15 pin 1. 8 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode
Expected Result Result Test satisfactory. Action Go to test 2
Other Result (Possible Cause) Action If problems are found, repair them. This test is complete.
Result No wire problems Action Go to test 3
Action If wire problems are found, repair or replace broken wire 132/ 133 (Orange).
Result No wire problems Action Go to test 4
Action If wire problems are found, repair or replace broken wire 132 (Orange) / 131 (White).
Result Test satisfactory Action Go to test 5
Result Diode is faulty, Action replace the diode.
Result No wire problems Action Go to test 6
Action If wire problems are found, repair or replace broken wire 624/ 622 (White) or 624/623 (White).
Result No wire problems Action Go to test 7
Action If wire problems are found, repair or replace broken wire 140 (Red) / 311 (Yellow).
Result No wire problems Action Go to test 8
Action If wire problems are found, repair or replace broken wire 138 (Orange) / 153 (Black).
Result Test satisfactory Action Go to test 9
Result Diode is faulty, Action replace the diode.
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ENGINE AND PTO IN - STARTING SYSTEM
Test Point N° 9 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-15 pin 2 and connector X-C23 pin 22. 10 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check Instrument Cluster pins 3, 9 ,11, 21, and 22.
Expected Result Result No wire problems Action Go to test 10
Other Result (Possible Cause) Action If wire problems are found, repair or replace broken wire 137 (White).
Action Result If resistance problems are found, No resistance problems replace the Instrument Cluster. Action The Ignition Switch S-008 has failed. Replace the IGNITION SWITCH S-008.
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Index ENGINE AND PTO IN - B STARTING SYSTEM - 80.A Cold start aid - Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Start control - Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools
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CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.
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SERVICE MANUAL TRANSMISSION, DRIVE AND PTO OUT
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents TRANSMISSION, DRIVE AND PTO OUT - C
TRANSMISSION Hydrostatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.F SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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CONSUMABLES INDEX IU
Consumable Molykote® G-N Metal assembly paste CASE Akcela Moly grease Loctite® 243 Loctite® 243 CASE Akcela Moly grease Loctite® 243 Loctite® 598 Ultra Black Loctite® 243 Loctite® 243 Loctite® 243 Loctite® 243 CASE AKCELA GEAR 135 H EP 85W-140
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Pump - Install mechanical hydrostatic pump
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Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install EH hydrostatic pump Pump - Install EH hydrostatic pump Motor - Install Drive motor Motor - Assemble Single speed drive motor Motor - Assemble Single speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Track drive motor
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TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F
TECHNICAL DATA Pump General specification 35cc EH Hydrostatic pump, used with small and medium frame models. . . . . . . . 8 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls
General specification 46cc EH Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification 46cc EHF Hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . 10 SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. . . . 12 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
General specification 53cc hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . . . . 13 SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification 46cc Hydrostatic tandem pump, used with large frame models. . . . . . . . . . . . . . . 14 SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Motor General specification for EH and Mechanical 325cc single speed motor on medium and small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SR130, SR150, SR175, SV185
General specification for mechanical 470cc single speed motor on medium and large frames . . . . . . . 16 SR200, SR220, SR250, SV250, SV300
General specification for 325cc 2 speed motor on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SR175, SV185, SR200
General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames . . . . 18 SR200, SR220, SR250, SV300
General specification for track drive 2 speed motor on medium and large frames . . . . . . . . . . . . . . . . . . 19 TR270, TR320, TV380
FUNCTIONAL DATA Pump Overview Hydrostatic pump model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE
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TRANSMISSION Hydrostatic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Command Remove Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Relief valve Pressure test Ground Drive Relief Valve - Manual control models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Pressure release valve Remove High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Pump Adjust Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
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Travel adjust (Stopping machine creep) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Adjust Hydraulic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Adjust EH Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Install mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Remove EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Remove Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Disassemble Hydrostatic pump unit disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Assemble Hydrostatic pump unit assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Disassemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Assemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Right hand pump - Disassemble Hydrostatic pump Sauer Danfoss 46cc . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Right hand pump - Visual inspection Hydrostatic pump visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Right hand pump - Measure Hydrostatic pump - measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
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Right hand pump - Assemble Hydrostatic pump assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Remove Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Charge pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Motor Remove Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Install Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Remove track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 TR270, TR320, TV380
Install track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 TR270, TR320, TV380
Assemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Disassemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Assemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Disassemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
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Assemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 TR270, TR320, TV380
Disassemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 TR270, TR320, TV380
Sensing system Remove Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
DIAGNOSTIC TRANSMISSION Hydrostatic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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CONSUMABLES INDEX IU
Consumable Molykote® G-N Metal assembly paste CASE Akcela Moly grease Loctite® 243 Loctite® 243 CASE Akcela Moly grease Loctite® 243 Loctite® 598 Ultra Black Loctite® 243 Loctite® 243 Loctite® 243 Loctite® 243 CASE AKCELA GEAR 135 H EP 85W-140
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Pump - Install mechanical hydrostatic pump
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Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install EH hydrostatic pump Pump - Install EH hydrostatic pump Motor - Install Drive motor Motor - Assemble Single speed drive motor Motor - Assemble Single speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Track drive motor
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Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls
Manufacturer
Bosch Rexroth
Type
Tandem, Axial Piston, EH control
Direction of Rotation
Clockwise
Nominal displacement
35 cm³ (2.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi)+/- 1.0 bar (15 psi)
Differential pressure A
360 bar (5220.0 psi)+/- 10 bar (145.0 psi)
Differential pressure B
360 bar (5220.0 psi)+/- 10 bar (145.0 psi)
Nominal voltage
14 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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Pump - General specification 46cc EH Hydrostatic pump SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer Type Direction of Rotation Nominal displacement Shaft test speed Charge pressure Differential pressure A Differential pressure B Nominal voltage Port
Bosch-Rexroth Tandem pump Clockwise 46 cm³ (3 in³) 2000 RPM 25 bar (363 psi +/- ) 1 bar (15 psi) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 14 V (A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure supply port
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Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer
Bosch Rexroth
Type
Combination pump
Direction of Rotation
Clockwise
Nominal displacement
46 cm³ (3 in³)
Maximum displacement port A
46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)
Maximum displacement port B
46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi +/- ) 1 bar (15 psi)
Relief valve A
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure A
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Relief valve B
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure B
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Nominal voltage
12 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Pump-Tandem - Axial piston
Direction of Rotation
Clockwise - When viewed looking into the input shaft
Front and rear displacments
35 cm³ (2.1 in³)
Manual swashplate displacement control
19.05 mm (0.75 in) square input shaft
Charge pressure relief setting
24 - 25 bar (348 - 363 psi) @ 1800 RPM
System pressure relief setting
345 bar (5003 psi) +5 / 0 %
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Pump - General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Combination pump
Direction of Rotation
Clockwise
Nominal displacement
46 cm³ (2.8 in³)
Maximum displacement port A
46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)
Maximum displacement port B
46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi +/- ) 1.0 bar (15 psi)
Relief valve A
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure A
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Relief valve B
385 bar (5582 psi +/- ) 10 bar (145 psi)
Differential pressure B
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Nominal voltage
12 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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Pump - General specification 53cc hydrostatic pump, used with large frame models. SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer
Rexroth
Type
Piston pump
Direction of Rotation
Clockwise
Nominal displacement
63 cm³ (3.8 in³)
Test speed
2800 RPM
Charge pressure
25 bar (363 psi)
Relief valve A
276 bar (4002 psi)
Differential pressure A
241 bar (3495 psi)
Relief valve B
207 bar (3002 psi)
Differential pressure B
182 bar (2639 psi)
Nominal voltage
12 V
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Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Pump-Tandem
Direction of Rotation
Clockwise
Front and rear displacments
46 cm³ (2.8 in³)
Bushed block rotating speed
up to 3600 RPM
Manual displacement control
Mechanical input, servo actuated with swashplate position feedback
Charge pump flow
30.3 l/min (8 US gpm) at 1800 RPMwith 48.9 °C (120 °F) oil
Charge pressure relief setting
24 - 25 bar (348 - 363 psi) @ 1800 RPM with 48.9 °C (120 °F) oil
System pressure relief setting
360 bar (5220 psi) +5 % set at 4.5 - 4.9 l/min (1.2 - 1.3 US gpm) with 48.9 °C (120 °F) oil
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Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models SR130, SR150, SR175, SV185
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
325 cm³/rev (20 in³/rev)
Speed
Maximum Operating: 330 RPM
Maximum Operating Pressure
System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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Motor - General specification for mechanical 470cc single speed motor on medium and large frames SR200, SR220, SR250, SV250, SV300
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
470 cm³/rev (28.7 in³/rev)
Speed
Maximum Operating: 385 RPM
System Operating Pressure
Differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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Motor - General specification for 325cc 2 speed motor on medium frames SR175, SV185, SR200
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
325 - 200 cm³/rev (19.8 - 12.2 in³/rev).
Speed
Maximum Operating: 330 RPM, 430 RPM at minimum displacement.
Output Shaft
10 Tooth RC 80 Sprocket
Maximum Operating Pressure
System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Displacement Shift Pressure
15 bar (218 psi) maximum.
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames SR200, SR220, SR250, SV300
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
470 - 282 cm³/rev (28.7 - 17.2 in³/rev).
Speed
Maximum Operating: 385 RPM, 465 RPM at minimum displacement.
Output Shaft
9 Tooth RC 100 Sprocket
Maximum Operating Pressure
414 bar (6000 psi) System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Displacement Shift Pressure
15 bar (218 psi) maximum.
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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Motor - General specification for track drive 2 speed motor on medium and large frames TR270, TR320, TV380
Manufacturer Type Direction of Rotation Displacement Speed Maximum Operating Pressure Brake Release Displacement Shift Pressure Ports
Bonfiglioli Radial or Axial piston with planetary reducer Dual rotation Two speed 50.9 - 33.1 cm³/rev (3.1 - 2.0 in³/rev) with 21.58:1 output reducer. Maximum Operating: 106 RPM in low range. 162 RPM in high range. 241 bar (3500 psi) Maximum differential relief pressure 345 bar (5003 psi). Fully released at 13 bar (189 psi). Maximum allowable brake pressure 49 bar (711 psi) 15 bar (218 psi) maximum. Service Ports: P1 and P2 2 Speed Control Port: Ps Drain Port: Dr
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Pump - Overview Hydrostatic pump model identification The skid steer product line is very versatile and comes with many options. The information below is to help with understanding what hydrostatic pumps may be equipped with certain models. Model SR130
Controls Mechanical Electro-hydraulic
SR150
Mechanical Electro-hydraulic
SR175
Mechanical Electro-hydraulic
SV185
Mechanical Electro-hydraulic
SR200
Mechanical Electro-hydraulic
SR220
Mechanical Electro-hydraulic
SR250
Mechanical
Electro-hydraulic
SV250
Mechanical Electro-hydraulic
SV300
Mechanical
Electro-hydraulic
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Hydrostatic Pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Model TR270
Controls Mechanical Electro-hydraulic
TR320
Mechanical
Electro-hydraulic TV380
Mechanical
Electro-hydraulic
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Hydrostatic Pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
TRANSMISSION Hydrostatic - Cleaning The hydrostatic system is a closed loop made up of the charging pump, piston pump, drive motors and the hoses between these components. The hydraulic cooler and reservoir are also part of the closed loop system. Any contamination in the hydrostatic system will stay in the closed loop, and probably cause damage. If the piston pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1.
Remove the piston pumps and at least the motor in the circuit that failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required.
2.
Disassemble, clean, and inspect the piston pumps and motor(s).
3.
Clean all hoses and tubes in the hydrostatic system. Remove each hose and tube from the machine. Flush and clean the hoses and tubes with hot soapy water. Hang and allow them to air dry. Hoses and tubes must be dry before installing.
4.
Install, inspected and repaired, or new piston pumps and motors.
5.
Change the hydraulic filter.
6.
Make sure that the hydraulic system is clean so that the charge pump will not cause new contamination in the closed loop. Remember that the oil cooler may have internal passages that can trap and hold contamination that can be dislodged later and cause a repeat failure.
NOTE: THE FOLLOWING PROCEDURE SHOULD BE USED FOR CLEANING HOSES, TUBES, AND FITTINGS. It is recommended that hoses, tubes and fittings be cleaned with a steam cleaner and dried with compressed air. 7.
Fasten the parts to a rack in a position as near to vertical as possible. This will allow water to drain as you flush parts.
8.
Clean the exterior surfaces of the parts thoroughly.
9.
Clean the interior surfaces of the parts. Use hot water and soap first. Then use clean hot water to rinse.
NOTE: If the steam cleaner does not have a soap injection system, spray an oil solvent into the parts. This will dissolve the oil film that holds contaminants inside the parts. Then use clean hot water to rinse. 10.
Fasten the parts in the rack so that the parts can be flushed from opposite ends. Repeat steps 8 an 9.
11.
Use compressed air to dry the inside of each part. Dry the parts from both ends to make sure all of the water is removed.
12.
Install caps or plugs in the ends of each hose, tube or fitting as soon as the parts are dry. This will prevent entry of contaminants. Remove the caps or plugs from the part only when the part is in position in the machine and you are ready to make the connection.
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Command - Remove Right hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A) NOTE: This procedure covers how to remove the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
3.
4.
Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
Locate the drive solenoid that needs to be removed. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of the hydrostatic pump.
Disconnect the connector (2) from the solenoid. Unscrew the cap (1).
Slide the solenoid off.
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Command - Install Right hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: This procedure covers how to install the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
Place the solenoid on to the valve body. See picture for location of solenoids. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of hydrostatic pump.
931001814
1
931001814
2
Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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Command - Remove Left hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A) NOTE: This procedure covers how to remove the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
3.
4.
Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
Locate the drive solenoid that needs to be removed. The left hand forward (1) and left hand reverse (2) solenoids are located near the auxiliary pump.
Disconnect the connector (1) from the solenoid. Unscrew the cap (2).
Slide the solenoid off.
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Command - Install Left hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: This procedure covers how to install the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
Place the solenoid on to the valve body. See picture for location of solenoids. The left hand reverse (1) and left hand forward (2) solenoids are located near the auxiliary pump.
931001814
1
931001814
2
Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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Relief valve - Pressure test Ground Drive Relief Valve - Manual control models SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Test Procedure: 1.
Raise and securely block the unit off the ground.
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 2.
3.
4.
Remove the brake release line from the tee fitting that connects to the B port (1) of the brake valve (2).
931002074
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931002074
2
Cap the tee fitting that connects to the B port (1) of the brake valve (2).
Connect a 690 bar (10,000 psi) pressure gauge to the high pressure loop gauge port. See the illustration below.
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HI01E019
3
Sauer M46 (1) Right Hand motor reverse test port, (2) Right Hand forward test port, (3) Left Hand motor test port, (4) Left Hand reverse test port
93111529
4
Sauer M35 right side view (1) front service line port, (2) rear service line port
93111523
5
Sauer M35 top view (1) front service line port, (2) rear service line port (opposite side bottom) 5.
Lower the cab and route the pressure gauge so that it can be viewed while running the unit from the operator’s seat. Start the unit and disengage interlocks to operate unit.
NOTE: An error will appear on the Instrument Cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 6.
If the hydraulic oil is not at operating temperature, run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 5 seconds. Then return the bucket control lever to NEUTRAL for 5 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).
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7.
Increase the engine speed to full throttle. Move the control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the control lever to NEUTRAL.
8.
The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the illustration below.
HI01E019_2
6
Sauer M46
93111523
7
Sauer M35 top view (1) bypass relief valves, (2) bypass relief valves (opposite side bottom)
93111529
8
Sauer M35 right side view (1) charge pressure relief valve 9.
Reconnect the brake lines to their original state.
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Relief valve - Pressure test (Machines Equipped with EH Controls) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 1.
Connect a 68 947 kPa (690 bar) (10,000 psi) pressure gauges to the test ports MA (1) and MB (2). See the figure below.
NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. NOTE: You will need two people to perform this test. The operator seat must be in the raised position to gain access to the hydrostatic pump. This test can be done in either ISO or H pattern. H pattern in preferred, only one pump will be actuated at a time.
20111250
2.
Connect a 4137 kPa (41.4 bar) gauge in the Yst port located on the top center of pump.
3.
Remove brake release lines from B port of the brake valve, plug lines and cap fittings in B port.
4.
If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).
5.
Run the engine at low idle. Move the ground drive control lever slowly to the FORWARD position.
6.
Increase the engine speed to full throttle. Slowly move the ground drive control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the ground drive control lever to NEUTRAL.
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1
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
7.
The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the figure below.
20111248
(1)Right Hand Forward Drive Circuit Relief Valve (2) Right Hand Reverse Drive Circuit Relief Valve
(3) Left Hand Forward Drive Circuit Relief Valve (4) Left Hand Reverse Drive Circuit Relief Valve
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2
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pressure release valve - Remove High pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Prior operation: To depressurize the system, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
Locate the high pressure relief valve(s) (1).
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2.
Remove the high pressure relief valve(s) (1).
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Next operation: Pressure release valve - Install High pressure relief (C.20.F).
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Pressure release valve - Install High pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Lubricate the threads (1) and support surface (2).
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1
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2
Thread the high pressure relief valve(s) (1) into the pump housing. Torque to 250 N·m (184.4 lb ft).
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Pressure release valve - Remove Low pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Prior operation: To depressurize the system, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
2.
Locate the low pressure relief valve (1).
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1
20115786
2
Remove the low pressure relief valve (1).
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3.
4.
Remove the spring collar (1).
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Remove the pressure spring (1).
Next operation: Pressure release valve - Install Low pressure relief (C.20.F).
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Pressure release valve - Install Low pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Place the collar (1) and pressure spring (2) onto the low pressure relief valve.
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1
20115485
2
Thread the low pressure relief valve (1) into the pump housing. Torque to 70 N·m (51.6 lb ft).
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Pump - Adjust Servo Piston Centering Spring SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: If more than one full turn of the servo adjusting screw was required when performing Pump - Travel adjust (C.20.F), or if the machine has the tendency to continue traveling in the direction that it was going last, both forward and reverse, check and adjust the locking nut on the adjusting screw at the servo piston centering spring. The only way for this nut to change adjustment, is if the internal centering spring should break, the spring retainer snap ring fails or the lock nut becomes loose. 1.
Remove the cap and external sealing nut (1).
2.
Remove the bolts retaining the servo piston cover in place.
3.
Rotate the piston cover off of the servo adjusting screw.
4.
Tighten or loosen the centering spring lock nut (2) until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
5.
Install the piston end covers and bolts.
6.
Perform Pump - Travel adjust (Stopping machine creep) (C.20.F) to center the servo piston.
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Pump - Travel adjust (Stopping machine creep) SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pump Adjustments Stopping Machine Creep 1.
In order to correct a creeping hydrostatic drive, a systematic diagnosis procedure must be followed. First, determine if it is the pump’s fault by disconnecting the control linkage to the servo control levers on the pump. If the problem disappears, inspect the linkage and correct the problem. Improper rod length, binding control bushings, binding control cables, etc., are some common problems. If after disconnecting the linkage, the system still moves, pump adjustments are available to correct the problem. If the only operational symptom noted is that one or both drive systems continue to move with the controls in neutral, adjustment of the servo control valve may possibly be all that is required (See Pump - Adjust Hydraulic Neutral (C.20.F)). If the unit does not track in a straight line or if one side tends to continue in the direction that it was going last, it is recommended to adjust the servo piston centering mechanism before adjusting the hydraulic neutral control.
Centering the Servo Piston 2.
The servo control piston has a very strong spring centering mechanism to return the pump to neutral condition when the hydraulic servo control is in neutral. A control rod from the centering mechanism runs through one end cover to allow for external adjustment. Use the following procedure to center the pilot servo piston:
NOTE: You will need two people to perform this procedure. NOTICE: The machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. 3.
Raise and secure block the unit off the ground.
NOTE: Never disconnect a hydraulic hose without depressurize the system, see PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). 4.
Disconnect and cap the charge pressure supply line (from the brake release solenoid valve) to the servo control inlet line. This is a small steel line that runs in between the two servos. This will allow you to adjust both pumps without hydraulic interference to the mechanical adjust you are performing.
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5.
Start the engine and run at full throttle.
6.
Loosen the jam nut and turn the servo adjusting screw in one direction until the tires just begin rotate, note the position of the adjusting screw. Turn the adjusting screw in the opposite direction until the tires just begin to rotate in the opposite direction, note the position of the screw. Repeat these steps again to verify the position of the screw when the tires begin to rotate. Center the adjusting screw between both positions and tighten the lock nut. NOTE: if more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted (see servo centering spring adjustment).
NOTE: If more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted. Perform Pump - Adjust Servo Piston Centering Spring (C.20.F). 7.
If the other pump requires adjustment, repeat Step 6 on the other pump.
8.
Stop the engine.
9.
Uncap and reconnect the charge pressure supply line
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Pump - Adjust Hydraulic Neutral SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Raise and secure block the unit off the ground.
2.
Start and run the engine at full throttle.
3.
Loosen the lock bolt for the servo control adjustment bracket. Move the bracket in one direction until the tires just begin to rotate in one direction and mark the position of the bracket. Move the bracket in the opposite direction until the tires just begin to rotate in opposite direction and mark the position of the bracket. Repeat the above steps to assure that the proper bracket position was marked. Center the adjustment bracket between the marks and tighten the lock bolt. Securely hold the bracket in position when tightening the lock bolt to prevent movement caused by the bolt head.
4.
After the bracket has been secured in position, gradually move the pump control lever away from the centered position in both directions. The servo control adjustment bracket is properly adjusted when an even amount of lever travel is required to begin tire rotation in both directions. Readjust as necessary to attain the centered position.
5.
If the other pump requires adjustment, repeat Steps 3 and 4 on the other pump.
6.
Stop the engine.
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Pump - Adjust EH Servo Piston Centering Spring SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
WARNING Crushing hazard! Before performing service under the machine, park the machine on a level surface, engage the parking brake, and stop the engine. Put blocks at the front and rear of the tires. Failure to comply could result in death or serious injury. W0350A
NOTE: Creep adjustments for the EH unit are less involved due to there being no linkage or hydraulic neutral adjustments. The procedure below is used to reduce drive creep in a electro-hydraulic machine. After checking charge pressure to confirm they are in spec there is only one adjustment, the centering of the servo piston. The procedure is very similar to a mechanical machine. 1.
Raise and securely block the unit off of the ground.
2.
Depressurize the system, PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) Deactivate the hydraulic servo control spool for the pump to be adjusted by disconnecting and capping the pressure supply hose (1). This completely takes the hydraulic control out of the servo and allows for a mechanical adjustment.
3.
Start the engine and run the engine at full throttle.
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4.
Tighten or loosen the centering spring lock nut until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
NOTE: If more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted. See step 5. 5.
Remove the cap and external sealing nut (1).
6.
Remove the bolts retaining the servo piston cover in place.
7.
Rotate the piston cover off of the servo adjusting screw.
8.
Tighten or loosen the centering spring lock nut (2) until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
9.
Install the piston end covers and bolts.
10.
Repeat steps as needed, if other pump requires adjustment.
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Pump - Remove mechanical hydrostatic pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A) NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 1.
2.
3.
Label and disconnect the four left hand side hydraulic hoses (1) and cap open ports
931002072
1
931002073
2
931002074
3
Label and disconnect the gear pump hydraulic tube (1) and supply hose (2) and cap open ports.
Label and disconnect right hand side hydraulic hoses (1) and cap open ports
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4.
5.
6.
7.
Disconnect control linkage hardware (1).
931002075
4
931002076
5
931002077
6
931002078
7
Disconnect electrical connection (1).
Using a metal rod as a brace across the pump attach lifting straps and hoist to support pump, as shown.
Remove the four pump mounting bolts (1) and (2).
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8.
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Using the hoist carefully remove pumps. 931002079
Next operation: Pump - Install mechanical hydrostatic pump (C.20.F)
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Pump - Install mechanical hydrostatic pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Pump - Remove mechanical hydrostatic pump (C.20.F) 1.
Before pump installation, apply MOLYKOTE® G-N METAL ASSEMBLY PASTE or CASE AKCELA MOLY GREASE to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil.
2.
Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines at the rear of the hydrostatic pump. After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.
3.
931002077
1
931002078
2
Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts (1) into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft). Apply LOCTITE® 243 to pump support bracket bolts (2). Install washer on bolts and install bolts. Tighten the pump support bracket bolts 55 - 60 N·m (40.6 - 44.3 lb ft).
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4.
5.
6.
7.
Connect electrical connection (1).
931002076
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931002075
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931002074
5
931002073
6
Connect control linkage (1).
Connect the right hand side hydraulic hoses (1).
Connect the rear hydraulic tube (1) and supply hose (2).
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8.
Connect the four left hand side hydraulic hoses (1) to the correct ports.
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Pump - Remove EH hydrostatic pump SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A) Oil cooler - Remove (A.10.A) 1.
Label and disconnect control wires (1) on bottom of pumps
931001961
1
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 2.
Label and disconnect the two front (1) and two rear (2) pump control connections.
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3.
4.
5.
6.
Label and disconnect the hydraulic oil temperature sender (1).
931001963
3
931001964
4
931001965
5
931001966
6
Label and disconnect the right hand side hydraulic hose (1).
Label and disconnect the oil supply hose (1) by loosening the hose clamp and cap ports.
Label and disconnect the top hydraulic tube (1) and cap open ports.
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7.
8.
9.
10.
Label and disconnect right hand side drive motor hoses (1) and cap open ports.
931001970
7
931001971
8
931001972
9
Label and disconnect left hand side drive motor hoses (1) and cap open ports.
Label and disconnect hydraulic hose (1) and cap open ports.
Label and disconnect case drain hose (1) and cap open ports.
931001963
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11.
12.
13.
Label and disconnect gear pump supply hose (1) and cap open ports.
931001955
11
931001956
12
931001974
13
931001928
14
Label and disconnect gear pump hydraulic tubes (1) and cap open ports.
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Place a lifting strap around the pump and using a hoist support the pump, as shown. 14.
Remove the two mounting bolts and washers (1) from the pump.
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15.
Using the hoist, carefully remove pumps.
931001976
Next operation: Pump - Install EH hydrostatic pump (C.20.F)
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Pump - Install EH hydrostatic pump SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Pump - Remove EH hydrostatic pump (C.20.F) NOTE: Before pump installation, apply CASE AKCELA MOLY GREASE to the pump and the coupling splines. Mount coupling star (1) to pump shaft with supplier logo facing out, toward the engine. Set coupling to dimension shown in the image below. Torque set screws to 25.7 - 28.3 N·m (19.0 - 20.9 lb ft) . Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 1.
2.
3.
Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines (1) at the rear of the hydrostatic pump. The distance (X) should be 49 mm (1.9 in) . After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.
93111555A
1
931001928
2
931001956
3
Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft).
Connect gear pump hydraulic hoses (1) as shown.
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4.
5.
6.
7.
Connect the gear pump supply hose (1) and tighten hose clamp.
931001955
4
931001963
5
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6
931001971
7
Connect case drain hose (1) and secure with clamp.
Connect hydraulic hose (1), as shown.
Connect left hand side drive motor hoses (1).
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8.
9.
10.
11.
Connect right hand side motor hoses (1).
931001970
8
931001966
9
Connect the top hydraulic hose (1).
Connect the oil supply hose (1) and tighten hose clamp.
931001965
10
931001964
11
Connect right hand side hydraulic hose (1).
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12.
13.
14.
Connect hydraulic oil temperature sender (1) and secure with nut.
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12
20111248
13
931001961
14
Connect the front (1) and rear pump control connections (2).
Connect the sensor wires (1) located on the bottom of pumps.
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Pump - Install Gear pump NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1.
2.
Install gear pump (1) and retaining bolts (2). Tighten bolts to torque.
931002073
1
931002073
2
931001955
3
Connect gear pump hydraulic tube (1).
NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, connect second hydraulic tube.
3.
Connect gear pump supply hose (1).
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Pump - Remove Gear pump WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A
Prior operation: For depressurizing the hydraulics, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1.
2.
Label and disconnect gear pump supply hose (1). Cap open ports.
931001955
1
931002073
2
931002073
3
Label and disconnect gear pump hydraulic tube (1). Cap open ports.
NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, label and remove second hydraulic tube. Cap open ports.
3.
Remove the gear pump retaining bolts (1). Remove gear pump.
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Pump - Disassemble Hydrostatic pump unit disassemble SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Some types of failures will require the disassembly of the tandem pump for cleaning and inspection. If there is failure in the drive motors or tandem pump, disassemble both the rear and front pumps, the drive motors, and all hoses between the pumps and drive motors. 1.
2.
3.
Remove the bolts that fasten the pumps together.
83111565
1
83111566
2
83111567
3
Remove the nut and bracket from the stud.
Separate the pumps (1).
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4.
Remove the two O-rings (1) and back-up ring (2).
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Pump - Assemble Hydrostatic pump unit assemble SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
2.
3.
4.
Install new O-rings and back-up ring.
83111568
1
83111567
2
83111566
3
83111565
4
Install bracket and nut. Connect the front and rear pump together.
Torque the retaining nut to 102 N·m (75.2 lb ft)
Install the bolts that fasten the front and rear pumps together. Torque the bolts to 91 - 111 Nm ( 67 - 82 lb ft
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Pump - Disassemble Sauer Danfoss 35cc mechanical pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Separate the pumps by removing the left and right side pump mounting bolts (1).
20115788A
1
20105293N
2
20115791
3
Remove the coupling (1) and gerotor (2) assembly from the gerotor cover.
Note the orientation of the gerotor assembly (1) and pins (2) for reassembly into housing (3).
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4.
5.
6.
Remove pin (1) from the coupler. For inspection of the charge pump, refer to Charge pump - Inspect (C.20.F).
20115790
4
20115820
5
83115796
6
Remove the end cap mounting bolts (1) from the pump housing (2). Discard the gasket.
Remove the valve plate.
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7.
8.
9.
10.
Remove circuit relief valve (1) from both sides of end cap.
20115795
7
20115825
8
20115794
9
Remove charge relief plug (1).
Remove the needle bearing.
Remove cylinder and piston assembly.
83115797
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10
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11.
12.
13.
14.
Remove the thrust plate.
20115826
11
83115799
12
83115801
13
83115798
14
Remove pistons and guide.
Remove the retainer guide, washer, pins and pin retainer.
Install a bolt with two washers to compress the spring.
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15.
16.
17.
Remove retaining ring. Release the spring. Remove the spring seats and spring
83115800
15
20115787
16
83115802
17
Remove the snap ring (1).
Remove seal and retainer.
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18.
19.
20.
21.
Discard o-ring and seal.
83115804
18
83115806
19
83115803
20
20105288N
21
Remove drive shaft and bearing.
Remove snap ring and bearing from drive shaft.
Remove trunnion cover (1).
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22.
23.
Remove top trunnion cover bolts (1) and cover.
20115822
22
83115809
23
Remove swashplate and bearing.
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Pump - Assemble Sauer Danfoss 35cc mechanical pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Install a new seal in trunnion cap. Seal lip goes to inside.
83115810
1
83115811
2
83115812
3
Install bearing cone on the swash plate.
Install swash plate. Shaft comes out the side of housing nearest the serial number plate.
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4.
5.
6.
7.
Install the bearing, original shims, spacers, a new quad ring and blank trunnion cover.
83115805
4
83115807
5
20115822
6
20115829
7
Install the bearing cup, original shims, spacer, and new quad ring.
Install the trunnion cover. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft)
Remove approximately 0.1 mm (0.005 in) of shims from each of the trunnion shim packs. Assemble the trunnion assemblies with the reduced shim packs. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft). Move the control arm up and down while measuring the end play with a dial indicator. Add shims to provide a 0.1 - 0.1 mm (0.002 - 0.004 in) preload on the swash plate bearings. Add shims equally on each side of pump housing. The swash plate should move freely with a torque of 0.6 - 1.7 N·m (5 - 15 lb in) applied to the control arm.
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8.
9.
10.
Install the bearing and snap ring on the drive shaft. Install the drive shaft and bearing into the housing.
83115806
8
83115804
9
Install a new seal and o-ring in the seal retainer. Install the seal retainer and snap ring.
Install the thrust plate.
20115826
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10
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11.
12.
13.
Install the inner spring seat, spring and outer spring seat into the cylinder. Compress the spring with the bolt and washers and install the retaining ring.
83115800
11
83115798
12
83115801
13
83115799
14
Install the pin retainer flush with top of cylinder. Install the pins in the recesses of the splines. Install the washer then retainer guided on top of the pins.
Install the pistons in the slipper guide. Lubricate the pistons and cylinder block bores. Install the pistons into the cylinder block.
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14.
15.
16.
17.
Install the cylinder assembly into the housing. Turn the shaft to help align the splines. The cylinder must go into the housing until the slippers contact he thrust plate.
83115797
15
20115794
16
20115795
17
20115825
18
Install the needle bearing so 2.0 - 2.5 mm (0.08 - 0.1 in) protrudes above the end cap surface. Printed end of bearing cage must face up.
Install the two circuit relief valves, springs and plugs with new o-rings. Both relief valves are the same. Tighten to a torque of 40.7 - 67.8 N·m (30 - 50 lb ft).
Install the charge relief valve, shims, spring and poppet into the housing with a new o-ring. Tighten to a torque of 54.2 - 135.6 N·m (40 - 100 lb ft).
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18.
19.
20.
Install the valve plate on the end cap with the brass side toward the pump cylinder. The cut out notch on OD locates on the roll pin in the end cap. Do not interchange valve plates. RH Drive Pump valve plate (1), LH Drive Pump valve plate (2)
83115796
19
20115821
20
83115813
21
20105293N
22
Install the end cap with a new gasket. Tighten the socket head screws to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Rotate the shaft to assure correct assembly. When properly assembled, a torque of 2.3 - 5.7 N·m (1.7 - 4.2 lb ft) should be required to turn the shaft.
Install the coupling on the shaft. Assemble the two piston pumps using new o-rings.
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21.
Tighten the socket head screws (1) to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Check for proper internal assembly by slowly rotating the pump shaft while tightening these screws.
20115788A
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23
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump Right hand pump - Disassemble Hydrostatic pump Sauer Danfoss 46cc SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. Left side pump disassembly is the same. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Remove the charge pump cover. Note the position of the charge pump cover pin (1) for use during assembly.
83111569
1
83111570
2
83111571
3
Remove the coupling from the inner gear.
Remove the inner gear from the outer gear.
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4.
5.
6.
7.
Remove the outer gear from the charge pump cover.
83111572
4
83111573
5
83111574
6
83111575
7
Remove the bolt stud.
Remove the special bolts from the cover.
Remove the cover, the gasket, and the shaft assembly.
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8.
9.
10.
11.
Remove the swash plate.
83111576
8
83111577
9
Remove the retainer and the pistons.
Remove the guide.
83111578
10
83111579
11
Remove the cylinder block.
NOTE: Do not disassemble the cylinder block.
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12.
13.
14.
15.
Do not lose the three pins (1) that are inserted into the cylinder block. They must stay in position.
83111580
12
83111581
13
83111582
14
83111583
15
Remove the wear plate.
Remove the gasket.
Remove the snap ring from the seal.
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16.
17.
18.
19.
Fasten the cover in a vise with soft jaws. Use a prybar to remove the seal.
83111584
16
83111585
17
83111586
18
83111587
19
Remove the snap ring from the groove, just above the ball bearing.
Push the shaft out of the cover. Inspect the bearing on the shaft. Replace if necessary.
Inspect the bearings (1) on the cover. If the tan surface has worn through to the dark base, use new bearings.
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20.
21.
22.
23.
Remove the screws from the cover.
83111588
20
83111589
21
83111590
22
83111591
23
Pull out the piston assembly from the housing.
Remove and discard the gasket.
Fasten the piston assembly in a vise with soft jaws. Hold the special bolt in place. Remove the special nut. Ensure that the special bolt does not turn while removing the special nut.
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24.
Measure the distance between the top of the special bolt and the cover. Record that measurement.
25.
Thread the cover counterclockwise until it is removed from the special bolt.
26.
Fasten the piston in a vise with soft jaws. Hold the adjusting nut in place. Loosen the jam nut.
27.
28.
83111592
24
83111593
25
83111594
26
83111595
27
Hold the special bolt in place. Tighten the adjusting nut to push the outer spring guide down, and away from the retaining ring.
Remove the retaining ring.
NOTE: The retaining ring will be difficult to remove.
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29.
30.
31.
32.
Hold onto the end of the special bolt and pull out the spring assembly.
83111596
28
83111597
29
83111598
30
83111599
31
Thread the jam nut (1) and the adjusting nut (2) counterclockwise until they are removed from the special bolt. Separate the outer spring guide (3), spring (4), sleeve, and inner spring guide (5) from the special bolt.
Remove the piston from the housing. Remove and discard the O-rings, and the piston rings from each end of the piston (1).
Remove the screws from the cover.
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33.
34.
35.
36.
Remove the cover and discard the gasket.
83111600
32
83111601
33
83111602
34
83111603A
35
Go to the spool assembly. Mark the position of where the stop bracket is bolted. Repeat for the other side.
Remove the bolts and the spool assembly from the housing.
Remove the sleeve from the housing.
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37.
38.
39.
40.
Remove the lock nut and washer from the spool.
83111604
36
83111605
37
83111606
38
83111607
39
Remove and discard the backup ring (1) and O-ring (2) from the spool.
Remove and discard the backup ring (1) and O-ring (2) from the sleeve.
Remove the hex plug and shims for the charge pressure relief valve.
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41.
42.
43.
44.
Remove the shims from the hex plug. Save the shims for later use.
83111608
40
83111609
41
83111610
42
83111611
43
Remove the spring.
Remove the valve poppet with a slide hammer.
Mark the hex plug that is used for the circuit reliefcheck valve.
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45.
46.
47.
48.
Remove the hex plug.
83445485
44
83111612A
45
83111613A
46
83111614B
47
Remove the spring.
Remove the circuit relief-check valve.
Loosen the bypass valve.
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49.
50.
51.
Thread the bypass valve counterclockwise until it is removed.
83111615C
48
83115460
49
83115461
50
Remove and discard the O-ring (1) and backup ring (2).
Remove the plug.
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Pump Right hand pump - Visual inspection Hydrostatic pump visual inspection SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. 1.
Inspect the face of the cylinder block for wear, scoring, and other damage. Use a new cylinder assembly as necessary.
2.
Inspect the cylinder bores for wear, scoring, and other damage. Use new cylinder assembly as necessary.
3.
Inspect the bronze surface of the wear plate. Use a new wear plate as necessary.
4.
Inspect the parts of the charging pump for wear and damage. Use a new pump as necessary.
5.
Inspect the pistons for wear and damage, use new parts as necessary.
6.
Inspect the shaft for damage to the splines and wear at the seal surfaces.
7.
Inspect the bearings. Replace any damaged bearings.
8.
Inspect the circular relief valve seats in the housings.
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Pump Right hand pump - Measure Hydrostatic pump - measure SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. 1.
2.
Measure the free travel between the shoes and the pistons. If all the measurements are not equal to within 0.13 mm ( 0.005 in), use a new cylinder assembly.
83115462
1
83115463
2
Measure the thickness of each shoe. If the measurements are not equal to within 0.02 mm ( 0.0001 in), use a new cylinder assembly.
3.
Check the fit of the pistons in the bores. The piston must move freely with minimum clearance. Use a new cylinder assembly as necessary.
4.
Measure the gear tip clearance between the inner gear and the outer gear. Clearance must not be more than 0.13 mm ( 0.005 in).
5.
Measure the width of the inner gear and the outer gear. The width of each gear must be equal to within 0.05 - 0.06 mm ( 0.002 - 0.003 in).
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Pump Right hand pump - Assemble Hydrostatic pump assemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Install the plug. Tighten the plug to a torque of 0.9 1.3 Nm (8 - 12 lb in).
83115461Z
1
83115460Z
2
83111615L
3
Slide a new backup ring (2) and O-ring (1) into the grooves of the bypass valve.
Thread the bypass valve into the housing.
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4.
5.
6.
7.
Tighten the bypass valve to a torque of 9 - 13 Nm (84 - 120 lb in)
83111614Q
4
83111613H
5
83111612T
6
83445485V
7
Thread the circuit relief-check valve into the housing.
Insert the spring on top of the circuit relief-check valve.
Thread the plug on top of the spring. Tighten the plug to a torque of 115 - 230 Nm ( 85 - 170 lb ft).
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8.
9.
10.
11.
Use a slide hammer to insert the valve poppet into the housing for the charge pressure relief valve.
83111610T
8
83111609S
9
Insert the spring on top of the valve poppet.
Insert the necessary quantity of shims into the hex plug. Thread the hex plug on top of the spring. Tighten but do not overtighten.
83111607-
10
83111606H
11
Slide a new O-ring (2) and backup ring (1) into the grooves of the sleeve.
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12.
13.
14.
15.
Slide a new O-ring (2) and backup ring (1) into the grooves of the spool.
83111605S
12
83115464G
13
83111604P
14
83111603PNA55
15
Insert the spool into and through the stop bracket. Refer to the alignment mark made during disassembly Pump Right hand pump - Disassemble (C.20.F).
Slide the washer and nut onto the protruding threads of the spool. Hold the spool assembly in place. Tighten the nut, but do not overtighten.
Lubricate the sleeve. Insert the sleeve into the housing. Ensure that the notch on the end of the sleeve is properly aligned with the notch inside housing.
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16.
17.
18.
19.
Lubricate the spool. sleeve.
Insert the spool inside the
83115465H0
16
83111602AS
17
83111600HJ
18
83111599FUG
19
Refer to the alignment mark made during disassembly Pump Right hand pump - Disassemble (C.20.F). Ensure the marks are in alignment. Secure the spool assembly with two bolts.
Place the new gasket and cover onto the rim of the housing.
Secure the cover with screws.
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20.
21.
22.
23.
Slide the inner spring guide (5), sleeve, spring (4), outer spring guide (3), the adjusting nut (2), and the jam nut (1) onto the special bolt.
83111597I
20
83115466GH
21
83111598P
22
83111596RQWE
23
Hold the bolt assembly in place. Tighten the adjusting nut to begin compression of the spring.
Insert one new ring (2) and one O-ring (1) into the grooves on each end of the piston.
Fasten the piston in a vise with soft jaws. Hold onto the end of the of the special bolt to insert the spring assembly into the piston.
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24.
25.
26.
27.
Hold the special bolt in place. Tighten the adjusting nut until the outer spring guide is below the groove. This will allow space for the retaining ring.
83111594FHJ
24
83115467DB
25
83111594G
26
83115468KIJ
27
Install the retaining ring onto the spring assembly.
Slightly loosen the special bolt. Ensure that the spring and adjusting nut do not become loose.
Hold the adjusting nut and special bolt in place. Tighten the jam nut. Recheck the special bolt and spring. Verify that the spring did not become loose.
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28.
29.
30.
31.
Lubricate the piston with clean oil. Slide the piston into the housing.
83115469HY
28
83115470TRY
29
83115471GH
30
83111588SD
31
Slide a new gasket and cover onto the special bolt.
During disassembly, the measured distance between the top of the special bolt and cover was recorded. Pump Right hand pump - Disassemble (C.20.F). Thread the cover up or down the special bolt until the distance is equal to that recorded measurement.
Secure the cover with four screws. Tighten the screws to the torque of 11 - 15 Nm ( 96 - 132 lb in).
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32.
33.
Hold the special bolt in place. Slide the special nut (with the sealing surface side down) onto the special bolt. Tighten the special nut, but do not overtighten.
83115472DFH
32
83115473MIO
33
83115474KO
34
83115475DR
35
During disassembly, the bearings on the cover were inspected Pump Right hand pump - Disassemble (C.20.F). If one of the bearings need to be replaced, align and insert the cover roll pin into the hole of the bearing. This will ensure proper placement.
NOTE: If a new cover is being used, install new roll pins so the distance between the tops of the roll pins and the face cover are 2.3 - 2.8 mm ( 0.090 - 0.110 in).
34.
35.
During disassembly, the ball bearing for the shaft was inspected Pump Right hand pump - Disassemble (C.20.F). If the ball bearing for the shaft has been replaced, install one snap ring on each side of the ball bearing.
Fasten the cover in a vice with soft jaws. Firmly press the ball bearing and the shaft into the cover.
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36.
37.
38.
39.
Install the snap ring into the groove, just above the ball bearing.
83111585DFDFHFH
36
83115476ASDFG
37
83111583F
38
83111581DFF
39
Lubricate the lip of the seal with clean oil. Carefully press the new seal with the lip down, into the cover.
Install the snap ring into the seal.
Lubricate the wear plate with clean oil. Align the notch on the wear plate with the roll pin that is located inside the cylinder port. Insert the wear plate with the bronze surface side up, into the cylinder port.
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40.
41.
42.
43.
Ensure that the three pins are still inserted in the cylinder block.
83111580DFFG
40
83115477WEED
41
83111579CVBNJ
42
83115480SDF
43
Hook the retaining collar and slide it up the splines until it reaches the top.
Insert the cylinder block into the pump.
Align and install the guide on top of the pins.
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44.
45.
46.
47.
Slide the retainer on top the guide. Ensure that the holes of the retainer are properly aligned with the holes of the cylinder block
83115479ASD
44
83115480SDF
45
83115481X
46
83115482MKP
47
Lubricate the pistons with clean oil. Insert one piston into each aligned hole of the retainer and cylinder block. Ensure that the guide is still properly positioned on top of the three pins.
If a new swash plate or pin is being used, go to the underside of the swash plate. Insert the pin into the top, center slot. Press down on the pin until the distance between the top of the pin and the swash plate is 8.4 - 8.9 mm ( 0.33 - 0.35 in).
Slide the guide (1) onto the pin located on the side of the swash plate.
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48.
49.
50.
51.
Install the swash plate. The pin must engage the slot in the body of the control valve. The retainer must engage the groove in the piston.
83111576CV
48
83115483FN
49
83115484I
50
83111574WER
51
Place a new gasket on the outside rim.
Carefully place the cover and the shaft assembly onto the gasket. Rotate the shaft to align the support with the cylinder block.
Secure the cover with special bolts. Use the bolts to evenly draw the cover to the housing. Tighten the 3/8 in special bolt to a torque of 53 - 64 Nm 39 - 47 lb ft. Tighten the 7/16 in special bolts to a torque of 81 - 100 Nm ( 60 - 74 lb ft).
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52.
53.
54.
55.
Insert the bolt stud into the housing.
83111573CFF
52
83111572HJU
53
83111571BL
54
83111570DF
55
Slide the outer gear into the charge pump cover.
Slide the inner gear into the outer gear.
Align the coupling pin with the inner gear slot. Slide the coupling into the inner gear.
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56.
Lubricate the charge pump cover with clean oil. Align the cover pin (1) with the hole found at the top of the housing. Slide the cover onto the cylinder block and into the housing.
83111569FTR
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56
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump Left hand pump - Disassemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Disassembly and inspection for the left pump is the same as the right pump except for the shaft and end cover. Please refer to Pump Right hand pump Disassemble (C.20.F).
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Pump Left hand pump - Visual inspection SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Visual inspection for the left pump is the same as the right pump. Please refer to Pump Right hand pump - Visual inspection (C.20.F).
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Pump Left hand pump - Measure SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Measuring the left pump is the same as the right pump. Please refer to Pump Right hand pump Measure (C.20.F).
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Pump Left hand pump - Assemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
The assembly of the left pump is the same as the right pump except for the shaft and end cover. Repeat steps as necessary for the left pump. Please refer to Pump Right hand pump - Assemble (C.20.F).
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Pump - Remove Drive shaft seal SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: To remove the gear pump, refer to Pump - Remove Gear pump (C.20.F) NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
2.
3.
Locate the drive shaft seal (1).
20115485
1
20115783
2
20115784
3
Remove snap ring (1).
Screw in self tapping screw(s) (1) into the holes (2) fitted with rubber. Pull out shaft seal with pliers.
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Next operation: Pump - Install Drive shaft seal (C.20.F)
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Pump - Install Drive shaft seal SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Lubricate the lip of the seal (1) with clean oil.
20115827
1
83115476
2
20115783
3
Carefully press the new seal, with the lip down, into the cover.
NOTE: Be careful not to press the seal to far in.
3.
Insert the snap ring (1).
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Charge pump - Install SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is the same. 1.
2.
3.
Install the wear plate (1).
83115517
1
20115828
2
83115515
3
Check that the locating pin (1) and channels (2) are correct (direction of rotation Clockwise looking on the drive shaft).
Install the coupler (1).
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PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.
84423866 25/07/2011 EN
SERVICE MANUAL ENGINE AND PTO IN
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
84423866 25/07/2011
B
Contents ENGINE AND PTO IN - B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
84423866 25/07/2011
B
ENGINE AND PTO IN - B ENGINE - 10.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B ENGINE - 10.A
SERVICE ENGINE Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SR130, SR150, SR175, SV185
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SR130, SR150, SR175, SV185
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
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ENGINE AND PTO IN - ENGINE
ENGINE - Remove SR130, SR150, SR175, SV185
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A).
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ENGINE AND PTO IN - ENGINE
1.
2.
3.
Remove the hood strut (1) from hood
931001682
1
931002025
2
931002026
3
Remove hood mounting hardware (2) from left and right hand side
Remove the hood (3).
4.
Remove the rear access door refer to Engine hood - Remove (E.20.A).
5.
Drain the engine oil.
6.
Remove the radiator refer to Radiator - Remove (B.50.A).
7.
Remove the oil cooler refer to Oil cooler - Remove (A.10.A).
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8.
9.
10.
11.
Remove the four mounting bolts (4) and slide the fan off the hub.
931002027
4
931002028
5
931002029
6
931002030
7
Remove the five mounting bolts (5) retaining the muffler inlet pipe mounting flange to the turbocharger and remove muffler.
Remove the two retaining bolts (6) from the muffler support.
Disconnect air restriction sensor (7).
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ENGINE AND PTO IN - ENGINE
12.
13.
14.
15.
Loosen the hose clamps on the intake tube at both ends, remove the intake tube (8), cover turbocharger inlet to avoid entry of debris.
931002031
8
931002032
9
Remove air cleaner housing (9).
Loosen hose clamp and remove upper radiator hose (10) from engine.
931002033
10
931002034
11
Disconnect the glow plug connection (11). Remove wire clamp (12).
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ENGINE AND PTO IN - ENGINE
16.
17.
18.
19.
Disconnect the starter connections (13).
931002035
12
931002036
13
931002037
14
931002038
15
Disconnect the alternator connection (14).
Disconnect temperature sender wire (15).
Disconnect oil pressure sender wire (16) and wire clamp (17).
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ENGINE AND PTO IN - ENGINE
20.
21.
22.
Disconnect throttle cable by removing the nut (A)and bolt (B) from the throttle body. Remove cable support clamp (C) by loosening the two hex head bolts (D).
931002039
16
931002040
17
931002042
18
Disconnect wire harness (18) and clamps (19) from the top of the flywheel housing.
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
Place a suitable container under lines to prevent spillage and remove the fuel supply line (20). 84423866 25/07/2011
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ENGINE AND PTO IN - ENGINE
23.
24.
25.
Remove the fuel return line (21).
931002041
19
931002043
20
931002044
21
931002045
22
Disconnect the spade connector (E)from the back side of the fuel shut off solenoid.
Place a suitable container under the remote engine oil filter lines. Label and disconnect oil filter lines (22).
NOTE: Cap the ends to avoid entry of debris.
26.
Disconnect the ground from the engine (23) to the battery quick disconnect.
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ENGINE AND PTO IN - ENGINE
27.
28.
29.
30.
Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate
931002046
23
931002050
24
931002047
25
931002048
26
Remove engine oil pan drain hose clamp (F).
Remove the front engine mounts (25).
Remove the rear engine mount (26).
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ENGINE AND PTO IN - ENGINE
31.
32.
33.
Remove the four mounting bolts (27) from the fixed hood, remove hood.
931002049
27
931002051
28
931002052
29
931002053
30
Place a suitable support beam across the skid steer frame. Tie a suitable strap around the pump and secure to the support beam, as shown.
DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A
Attach proper lifting straps to the eye hooks (28) provided on the engine.
34.
Use a suitable hoist to carefully lift the engine slightly rearward to separate from the hydraulic pumps. Once free, lift the engine and remove from the rear of chassis.
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ENGINE AND PTO IN - ENGINE
ENGINE - Remove SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A). Prior operation: Radiator - Remove (B.50.A)
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ENGINE AND PTO IN - ENGINE
1.
2.
Remove the hood struts (1) from each side by gently prying the retaining clip (2) just enough to release the strut.
1
931002025
2
931002026
3
931001896
4
Remove hood mounting hardware (1) from left-hand and right-hand side of the hood.
3.
Remove the hood (1).
4.
Remove the rear access door refer to Engine hood - Remove (E.20.A).
5.
Remove the oil cooler refer to Oil cooler - Remove (A.10.A).
6.
931001887
Remove the three mounting bolts (1) retaining the muffler inlet pipe mounting flange to the turbocharger, cover turbocharger inlet the avoid entry of debris.
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ENGINE AND PTO IN - ENGINE
7.
8.
9.
10.
Remove the four retaining bolts (1) from the muffler support.
931001895
5
931002030
6
931001898
7
931001899
8
Disconnect air restriction sensor (1).
Loosen the hose clamps on the intake tube at both ends, remove the air cleaner to turbo charger tube (1).
Remove the engine cover (1).
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ENGINE AND PTO IN - ENGINE
11.
Remove air cleaner housing (1) by removing the three bolts (2).
931001900
12.
13.
14.
9
Loosen hose clamp (1) and remove upper radiator hose (2) from engine.
931001903
10
931001908
11
931001909
12
Disconnect the alternator electrical connections (1).
Disconnect the starter electrical connections (1).
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ENGINE AND PTO IN - ENGINE
15.
16.
17.
Disconnect ground connection (1) below the starter (2).
931001910
13
931001911
14
931002113
15
Unplug wire harness connection (1).
Disconnect low pressure line (1) from the Air-conditioning compressor (2).
NOTE: Place a suitable container under the machine to catch any lost fuel.
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ENGINE AND PTO IN - ENGINE
18.
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
WARNING
931001917
16
931001919
17
931001922
18
Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
Remove the fuel return line (1). 19.
20.
Remove the fuel supply line (1).
Remove the throttle cable (1).
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ENGINE AND PTO IN - ENGINE
21.
22.
23.
24.
Place a suitable container under the remote engine oil filter lines (1). Label and disconnect oil filter lines.
931001923
19
931002046
20
931001925
21
931001926
22
Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate
Disconnect fuel pump electrical connection (1).
Disconnect harness (1) from connector (2).
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ENGINE AND PTO IN - ENGINE
25.
26.
27.
28.
Place a suitable support beam (1) across the skid steer frame. Tie a suitable strap (2) around the pump (3) and secure to the support beam, as shown.
931001929
23
931001928
24
931001936
25
931001944
26
Remove the two pump mounting bolts (1).
Disengage pump assembly (1) from engine housing (2).
DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A
Attach proper lifting straps (1) to support the engine (2).
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ENGINE AND PTO IN - ENGINE
29.
30.
31.
32.
Remove the front and rear engine mounts (1).
931001933
27
931001938
28
931002050
29
931001943
30
Raise the engine slightly as shown.
Remove engine oil drain hose clamp (1).
Remove heater hose clamp (1).
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ENGINE AND PTO IN - ENGINE
33.
Remove upper heater hose (1).
NOTE: Use a suitable device to catch any coolant not drained previously.
34.
35.
931002114
31
931001940
32
931001946
33
Remove lower heater hose (1).
WARNING Heavy object! ALWAYS use adequate lifting equipment (heavy-duty hoist, loader, or forklift) to lift the component. Failure to comply could result in death or serious injury. W0101A
Remove engine (1) from the chassis.
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ENGINE AND PTO IN - ENGINE
ENGINE - Install SR130, SR150, SR175, SV185
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
Attach proper lifting straps to the eye hooks (1) provided on the front right and rear left of the engine.
931002052
1
931002053
2
931002046
3
Using a suitable hoist carefully lower engine into engine compartment on the skid steer.
3.
Slowly orient the hydraulic pump coupler to the adapter on the engine ensuring the attachment of engine plate to flywheel housing.
4.
Attach engine to hydraulic pump mounting plate using the twelve mounting bolts (2).
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ENGINE AND PTO IN - ENGINE
5.
6.
7.
8.
Remove support brace and straps from hydraulic pump.
931002051
4
931002047
5
931002048
6
931002049
7
Install front engine mounting bolts (3).
Install rear engine mounting bolt (4).
Install Fixed hood and secure with hardware (5).
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ENGINE AND PTO IN - ENGINE
9.
10.
11.
12.
Install engine oil pan drain hose into clamp (6).
931002050
8
931002045
9
Connect ground from the quick battery disconnect to the engine (7).
Connect remote engine oil filter lines (8).
931002044
10
931002043
11
Connect the spade connector to the back of the fuel shut off solenoid (9).
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ENGINE AND PTO IN - ENGINE
13.
14.
15.
16.
Connect the fuel return line (10).
931002041
12
931002042
13
931002040
14
931002039
15
Connect the fuel supply line (11).
Connect the wire harness (12) and clamps (13) to the top of the flywheel housing..
Connect throttle cable by installing the nut (A)and bolt (B) to the throttle body. Install cable support clamp (C) and tighten the two hex head bolts (D).
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ENGINE AND PTO IN - ENGINE
17.
18.
19.
20.
Connect oil pressure sender wire (14) and support (15).
931002038
16
931002037
17
931002036
18
931002035
19
Connect temperature sensor wire (16).
Connect alternator connection (17).
Connect starter connections (18).
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ENGINE AND PTO IN - ENGINE
21.
22.
23.
24.
Connect glow plug connection (19) and wire clamp (20).
931002034
20
931002033
21
931002032
22
931002031
23
Install upper radiator hose (21) to engine and tighten hose clamp.
Install air cleaner housing to bracket, secure with mounting bolts (22).
Install air cleaner to turbo hose (23) and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE
25.
26.
27.
28.
Connect air restriction sensor (24).
931002030
24
931002028
25
931002029
26
931002027
27
Install muffler inlet pipe mounting flange to turbocharger and secure with the five mounting bolts (25).
Install the two retaining bolts (26) to the muffler support.
Place fan on hub and secure with the four retaining bolts (A).
29.
Install oil cooler refer to Oil cooler - Install (A.10.A).
30.
Install radiator refer to Radiator - Install (B.50.A).
31.
Add engine oil.
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ENGINE AND PTO IN - ENGINE
32.
Fill hydraulic oil reservoir refer to Reservoir - Filling (A.10.A).
33.
Fill coolant refer to Radiator - Filling (B.50.A).
34.
Lift engine hood into place on the top of the skid steer.
35.
36.
931002026
28
931002025
29
931001682
30
Install the left and right hand side hood mounting bolts (27).
Connect the hood support strut (B) to the left hand side of hood.
37.
Install rear access door refer to Engine hood - Install (E.20.A).
38.
Lower cab refer to Tilt system - Lower (E.34.A).
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ENGINE AND PTO IN - ENGINE
ENGINE - Install SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
3.
Attach proper lifting straps to the eye hooks provided on the front and rear of the engine, as shown.
931001946
1
931001944
2
931001936
3
Using a suitable hoist carefully lower engine into engine compartment on the skid steer.
Carefully orient hydraulic pump coupler to adapter on the engine ensuring attachment of engine plate to flywheel housing.
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ENGINE AND PTO IN - ENGINE
4.
5.
6.
7.
Install pump mounting bolts and washers (1) into pump housing.
931001928
4
931001933
5
931002047
6
931001929
7
Install the two rear engine mounting bolts and bushings (2).
Install the two front engine mounting bolts and bushings (3).
Verify pump mounting bolts are secure and carefully remove support brace (4)and straps (5) from pump.
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ENGINE AND PTO IN - ENGINE
8.
9.
10.
11.
Connect the lower heater hose (6).
931001940
8
931002114
9
Connect the upper heater hose (7).
Attach heater hose support clamp (8).
931001943
10
931002050
11
Attach engine oil pan drain hose support clamp (9).
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ENGINE AND PTO IN - ENGINE
12.
13.
14.
15.
Connect the wiring harness connection (10).
931001926
12
931001925
13
931001923
14
931001922
15
Connect the fuel pump wire connection (11).
Connect the two remote oil filter lines (12) and (13) as previously labeled.
Connect throttle cable by installing the nut (A) and bolt (B) to the throttle body. Install cable support clamp and tighten the two hex head bolts (C).
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ENGINE AND PTO IN - ENGINE
16.
17.
18.
19.
Connect fuel supply line (14).
931001919
16
931001917
17
931002113
18
931001911
19
Connect fuel return line (15).
Connect low pressure line to the air condition compressor (16).
Connect wire harness connection (17) located on left hand side above motor mount.
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ENGINE AND PTO IN - ENGINE
20.
21.
22.
23.
Connect the ground to engine from battery quick disconnect (18) and cab ground (19).
931001910
20
931001909
21
931001908
22
931001903
23
Connect the two starter connections (D) and (E).
Connect the two alternator connections (F) and (G).
Install upper radiator hose (20) to engine and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE
24.
25.
26.
27.
Install the three mounting bolts (21) that secure air cleaner housing and bracket to frame.
931001900
24
931001899
25
931001898
26
931001897
27
Install the fixed hood and secure with hardware (22).
Connect air cleaner to turbo hose (23).
Connect air restriction sensors electrical connection (24).
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ENGINE AND PTO IN - ENGINE
28.
29.
30.
31.
Install the four mounting bolts from the muffler brackets (25).
931001895
28
931001896
29
931001894
30
931001887
31
Install the three retaining bolts (26) to the exhaust manifold mounting flange .
Attach lifting straps through the engine hood and hoist in mounting location.
Install left and right hand side hood mounting hardware (27).
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ENGINE AND PTO IN - ENGINE
32.
33.
34.
35.
Connect left and right hand side hood struts (28).
931001887
32
931001893
33
931001890
34
931001889
35
Connect condenser fan electrical connection (29).
Connect top and bottom air condition condenser lines (30).
Install air condition refrigerant.
Next operation: Oil cooler - Install (A.10.A). Next operation: Radiator - Install (B.50.A). 84423866 25/07/2011
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ENGINE AND PTO IN - ENGINE
Next operation: Reservoir - Filling (A.10.A). Next operation: Radiator - Filling (B.50.A). Next operation: Tilt system - Lower (E.34.A).
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Index ENGINE AND PTO IN - B ENGINE - 10.A ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SR130, SR150, SR175, SV185
ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SR130, SR150, SR175, SV185
ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
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ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A
TECHNICAL DATA Sensing system General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Throttle command Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system - General specification Resistance Fuel Bar Conversion Resistance Fuel Bar Conversion for Large Machines Resistance Low (in Ω) < 32 33 68 108 155 188 211 243
Resistance High (in Ω) 32 67 107 154 187 210 242 > 243
Bars 8 7 6 5 4 3 2 1
Resistance Fuel Bar Conversion for Medium Machines Resistance Low (in Ω) < 32 33 48 88 132 155 201 231
Resistance High (in Ω) 32 47 87 131 154 200 230 > 231
Bars 8 7 6 5 4 3 2 1
Resistance Fuel Bar Conversion for Small Machines Resistance Low (in Ω) 86 80 73 66 55 38 16 0
Resistance High (in Ω) > 86 85 79 72 65 54 37 15
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Bars 8 7 6 5 4 3 2 1
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Throttle command - Adjust 1.
2.
3.
Start the machine. Press and Hold Auxiliary Over Ride Button (1) for 2 seconds. Release button, and press to toggle (2) to next display setting. Continue to press and release button until RPM’s are displayed
931007504
1
93111552
2
93111549
3
Adjust the clevis (1) on the end of the foot pedal, so that with the first 5 degrees of handle movement the pedal starts to move. If the pedal does not move with the throttle handle, turn the clevis in to shorten the cable.
Loosen the jam nut (1), turn the stop bolt (2) IN several turns.
NOTE: Make sure the plunger is through the L-Bracket when the jam nut is tight. Plunger must move freely through L-bracket . Do not pinch the L-Bracket between plunger and washer. 4.
Place engine throttle in low idle position to adjust cable length on the engine. Turn the plunger thumb screw (1) in until cable (2) is fairly tight. If cable is too tight, the engine will not return to low idle. Idle should be approximately 1075 RPM +/- 75 RPM.
93111551
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4
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
5.
6.
Move hand throttle (1) to full position. Full throttle should be approximately 2675 RPM +/- 75 RPM.
93111550
5
93111549
6
Turn stop bolt (1) OUT until is contacts the pedal. Tighten the jam nut (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel tank - Remove WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
Prior operation: ENGINE - Remove (B.10.A) 1.
2.
Disconnect the fuel sender connector (1).
931002098B
1
931002098B
2
Label and disconnect fuel supply line (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
3.
4.
5.
Remove left hand side fuel tank bracket (3).
931002099B
3
931002100B
4
Remove right hand side fuel tank bracket (4).
Drain fuel from the tank using the drain plug located at the bottom of the tank.
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
6.
Remove fuel tank.
931002102B
Next operation: Fuel tank - Install (B.20.A)
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5
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel tank - Install WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
Prior operation: Fuel tank - Remove (B.20.A) 1.
2.
Position fuel tank into correct location on skid steer.
931002102B
1
931002099B
2
Install left hand side fuel tank bracket (1).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
3.
4.
5.
6.
Install right hand side fuel tank bracket (2).
931002100B
3
931002098B
4
931002098B
5
Connect fuel supply line (3).
Connect fuel sender (4).
Install engine refer to ENGINE - Install (B.10.A).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system Level sensor - Remove Fuel Level Sender 1.
2.
3.
Locate and open rear engine hood (1).
93111006AB
1
931002032
2
931002098
3
Remove hardware (1) from air filter housing (2).
Disconnect connector X-14 (1) from the fuel level sender B-001 (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
4.
5.
6.
Label and disconnect the fuel lines (1).
931002098
4
931002098
5
931002098
6
Remove hardware (1) and fuel level sender retainer (2).
Remove fuel level sender B-001 (1) from fuel tank.
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Sensing system Level sensor - Install Fuel Level Sender 1.
2.
3.
4.
Insert fuel level sender B-001 (1) into the fuel tank.
93111533
1
93111534
2
931002098
3
931002098
4
Place the fuel level sender retainer (1), and hardware (2) onto fuel tank. Tighten hardware.
Reconnect the fuel lines (1).
Reconnect connector X-14 (1) to the fuel level sender B-001 (2).
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
5.
6.
Install air filter housing (1) and bolts (2). Tighten the bolts.
931002032
5
93111006AB
6
Close rear engine hood (1).
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Index ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sensing system - General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sensing system Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Throttle command - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A
SERVICE Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Sensing system Air cleaner restriction - Remove 1.
2.
3.
4.
Locate and open rear engine hood (1) and service door (2).
93107449A1
1
931002032
2
931002030
3
931002030
4
Remove hardware (1) from air filter housing (2).
Remove hose clamp (1) from air cleaner assembly (2).
Remove clip (1) securing connector X-508. Disconnect connector X-508 from the air filter restriction switch B-016 (2).
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
5.
Unscrew the air filter restriction switch B-016 (1) by hand from air cleaner assembly (2).
931002030
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5
ENGINE AND PTO IN - AIR INTAKE SYSTEM
Sensing system Air cleaner restriction - Install 1.
2.
3.
4.
Install the air filter restriction switch (1) into the air cleaner assembly.
931002030
1
931002030
2
931002030
3
931002032
4
Connect the connector (1) to the air filter switch, and insert clip (2).
Place hose clamp (1) over hose and connect to air cleaner assembly (2). Tighten the hose clamp.
Insert hardware (1), and attach air cleaner assembly (2) to mount.
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Index ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A Sensing system Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A
SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Remove WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A
Prior operation: Radiator - Drain fluid (B.50.A). 1.
2.
3.
Disconnect the radiator over-flow hose, (1), at the radiator and elevate above the overflow reservoir allowing fluid to drain into over-flow. Hose can be draped anywhere it is save from damage.
931001645
1
931001648
2
931001650
3
Loosen the hose clamp and remove the upper radiator hose from the radiator (2).
Loosen the top mounting bolts from both left hand side and right hand side of radiator (3).
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
4.
5.
6.
Tilt the top of the radiator out, as shown.
931001653
4
931002071
5
931002060
6
931002061
7
Loosen the hose clamp and disconnect lower radiator hose (4).
Remove the two radiator support clips (5) from the support pins on the right hand side of bracket. Push the support pins out.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
7.
8.
Remove left hand side support hardware (6) from the bottom of the bracket.
931002062
8
931001654
9
Remove radiator along with left hand side bracket.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Install 1.
2.
3.
Slide radiator back in right hand side mounting bracket (1).
931001654
1
931002062
2
931002071
3
Install left hand side bracket support hardware (2).
Tilt radiator out and connect lower radiator hose (3) and tighten hose clamp.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
4.
5.
6.
Push right hand side radiator support pins through bracket and install retaining clips (4).
931002060
4
931002061
5
931001653
6
931001650
7
Tilt radiator in and align top brackets.
Tighten top mounting bolts (5) on both left and right hand side.
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
7.
8.
9.
Connect the upper radiator hose (6) to the radiator and tighten hose clamp.
931001648
8
931001645
9
Connect over flow hose (7).
After the radiator has been installed refer to the following procedure for filling the radiator. Radiator Filling (B.50.A).
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Drain fluid WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A
1.
If engine is HOT do not drain cooling system. Allow the system to cool before draining the radiator.
2.
Open the rear access door.
3.
Drain the engine coolant system by loosening the drain valve (1), and drain the coolant into a suitable container. When the radiator is empty, tighten the drain valve
931001644
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1
ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Filling CAUTION Burn hazard! Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir. Failure to comply could result in minor or moderate injury. C0031A
1.
2.
3.
Open the rear access door and remove the radiator cap (1) after the engine has cooled.
931001652
1
931001645
2
Fill the radiator with a 50% mixture of ethylene glycol engine coolant and 50% water mixture. The coolant level must be to the top of the radiator fill neck, just below the overflow tube (1). Install cap loosely (2).
Start and run the engine until it reaches operating temperature. Stop the engine and check the level of the coolant in the recovery bottle (2). Fill the recovery bottle with a 50% mixture of ethylene glycol engine coolant and 50% water mixture to the full level marked on the bottle. Once level is good tighten cap.
NOTICE: Do not remove the radiator cap from the radiator while the engine is HOT.
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Index ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE AND PTO IN - B STARTING SYSTEM - 80.A
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents ENGINE AND PTO IN - B STARTING SYSTEM - 80.A
FUNCTIONAL DATA Cold start aid Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC Start control Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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ENGINE AND PTO IN - STARTING SYSTEM
Cold start aid - Overview Engine preheat During cold starts, diesel engine preheating is completed by the use of glow plugs. Engines use glow-plugs in each combustion chamber to increase the temperature of the cylinder. Diesel engines rely solely on compression to raise the temperature of the air to a point where the diesel will combust spontaneously when introduced to the hot high pressure air. At normal temperature, the high pressure and spray pattern of the diesel ensures a controlled, complete burn. The piston rises, compressing the air in the cylinder; this causes the air's temperature to rise. By the time the piston reaches the top of its travel path, the temperature in the cylinder is very high. The fuel mist is then sprayed into the cylinder; it instantly combusts, forcing the piston downwards, thus generating power.
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ENGINE AND PTO IN - STARTING SYSTEM
Start control - Testing Ignition Switch NOTE: Wiring Wiring Wiring
Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 14 (A.30.A)
Test Point N° 1 Condition Use Fuse and relay box - Testing Main Power Relay Control (A.30.A) to check MAIN POWER RELAY. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-316 pin A. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-C23 pin 21. 4 Condition Disconnect connector X-316 from the IGNITION BACKFEED DIODE V-007 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 2 and connector X-C23 pins 9 and 11. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 1 and connector X-C23 pin 3. 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 6 and connector X-15 pin 1. 8 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode
Expected Result Result Test satisfactory. Action Go to test 2
Other Result (Possible Cause) Action If problems are found, repair them. This test is complete.
Result No wire problems Action Go to test 3
Action If wire problems are found, repair or replace broken wire 132/ 133 (Orange).
Result No wire problems Action Go to test 4
Action If wire problems are found, repair or replace broken wire 132 (Orange) / 131 (White).
Result Test satisfactory Action Go to test 5
Result Diode is faulty, Action replace the diode.
Result No wire problems Action Go to test 6
Action If wire problems are found, repair or replace broken wire 624/ 622 (White) or 624/623 (White).
Result No wire problems Action Go to test 7
Action If wire problems are found, repair or replace broken wire 140 (Red) / 311 (Yellow).
Result No wire problems Action Go to test 8
Action If wire problems are found, repair or replace broken wire 138 (Orange) / 153 (Black).
Result Test satisfactory Action Go to test 9
Result Diode is faulty, Action replace the diode.
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Test Point N° 9 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-15 pin 2 and connector X-C23 pin 22. 10 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check Instrument Cluster pins 3, 9 ,11, 21, and 22.
Expected Result Result No wire problems Action Go to test 10
Other Result (Possible Cause) Action If wire problems are found, repair or replace broken wire 137 (White).
Action Result If resistance problems are found, No resistance problems replace the Instrument Cluster. Action The Ignition Switch S-008 has failed. Replace the IGNITION SWITCH S-008.
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Index ENGINE AND PTO IN - B STARTING SYSTEM - 80.A Cold start aid - Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Start control - Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools
PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.
84423866 25/07/2011 EN
SERVICE MANUAL TRANSMISSION, DRIVE AND PTO OUT
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents TRANSMISSION, DRIVE AND PTO OUT - C
TRANSMISSION Hydrostatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.F SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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CONSUMABLES INDEX IU
Consumable Molykote® G-N Metal assembly paste CASE Akcela Moly grease Loctite® 243 Loctite® 243 CASE Akcela Moly grease Loctite® 243 Loctite® 598 Ultra Black Loctite® 243 Loctite® 243 Loctite® 243 Loctite® 243 CASE AKCELA GEAR 135 H EP 85W-140
PAGE
Pump - Install mechanical hydrostatic pump
C.20.F / 47
Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install EH hydrostatic pump Pump - Install EH hydrostatic pump Motor - Install Drive motor Motor - Assemble Single speed drive motor Motor - Assemble Single speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Track drive motor
C.20.F / 47 C.20.F / 47 C.20.F / 47 C.20.F / 55 C.20.F / 55 C.20.F / 126 C.20.F / 138 C.20.F / 141 C.20.F / 155 C.20.F / 157 C.20.F / 179
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TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
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Contents TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F
TECHNICAL DATA Pump General specification 35cc EH Hydrostatic pump, used with small and medium frame models. . . . . . . . 8 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls
General specification 46cc EH Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification 46cc EHF Hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . 10 SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. . . . 12 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
General specification 53cc hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . . . . 13 SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
General specification 46cc Hydrostatic tandem pump, used with large frame models. . . . . . . . . . . . . . . 14 SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Motor General specification for EH and Mechanical 325cc single speed motor on medium and small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SR130, SR150, SR175, SV185
General specification for mechanical 470cc single speed motor on medium and large frames . . . . . . . 16 SR200, SR220, SR250, SV250, SV300
General specification for 325cc 2 speed motor on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SR175, SV185, SR200
General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames . . . . 18 SR200, SR220, SR250, SV300
General specification for track drive 2 speed motor on medium and large frames . . . . . . . . . . . . . . . . . . 19 TR270, TR320, TV380
FUNCTIONAL DATA Pump Overview Hydrostatic pump model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE
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TRANSMISSION Hydrostatic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Command Remove Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Relief valve Pressure test Ground Drive Relief Valve - Manual control models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Pressure release valve Remove High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Pump Adjust Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
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Travel adjust (Stopping machine creep) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Adjust Hydraulic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Adjust EH Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Install mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Remove EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Remove Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Disassemble Hydrostatic pump unit disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Assemble Hydrostatic pump unit assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Disassemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Assemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Right hand pump - Disassemble Hydrostatic pump Sauer Danfoss 46cc . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Right hand pump - Visual inspection Hydrostatic pump visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Right hand pump - Measure Hydrostatic pump - measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
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Right hand pump - Assemble Hydrostatic pump assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Left hand pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Remove Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Charge pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Motor Remove Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Install Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Remove track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 TR270, TR320, TV380
Install track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 TR270, TR320, TV380
Assemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Disassemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Assemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
Disassemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
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Assemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 TR270, TR320, TV380
Disassemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 TR270, TR320, TV380
Sensing system Remove Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Remove Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Install Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
DIAGNOSTIC TRANSMISSION Hydrostatic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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CONSUMABLES INDEX IU
Consumable Molykote® G-N Metal assembly paste CASE Akcela Moly grease Loctite® 243 Loctite® 243 CASE Akcela Moly grease Loctite® 243 Loctite® 598 Ultra Black Loctite® 243 Loctite® 243 Loctite® 243 Loctite® 243 CASE AKCELA GEAR 135 H EP 85W-140
PAGE
Pump - Install mechanical hydrostatic pump
C.20.F / 47
Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install mechanical hydrostatic pump Pump - Install EH hydrostatic pump Pump - Install EH hydrostatic pump Motor - Install Drive motor Motor - Assemble Single speed drive motor Motor - Assemble Single speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Two speed drive motor Motor - Assemble Track drive motor
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls
Manufacturer
Bosch Rexroth
Type
Tandem, Axial Piston, EH control
Direction of Rotation
Clockwise
Nominal displacement
35 cm³ (2.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi)+/- 1.0 bar (15 psi)
Differential pressure A
360 bar (5220.0 psi)+/- 10 bar (145.0 psi)
Differential pressure B
360 bar (5220.0 psi)+/- 10 bar (145.0 psi)
Nominal voltage
14 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 46cc EH Hydrostatic pump SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer Type Direction of Rotation Nominal displacement Shaft test speed Charge pressure Differential pressure A Differential pressure B Nominal voltage Port
Bosch-Rexroth Tandem pump Clockwise 46 cm³ (3 in³) 2000 RPM 25 bar (363 psi +/- ) 1 bar (15 psi) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 14 V (A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure supply port
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer
Bosch Rexroth
Type
Combination pump
Direction of Rotation
Clockwise
Nominal displacement
46 cm³ (3 in³)
Maximum displacement port A
46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)
Maximum displacement port B
46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi +/- ) 1 bar (15 psi)
Relief valve A
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure A
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Relief valve B
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure B
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Nominal voltage
12 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Pump-Tandem - Axial piston
Direction of Rotation
Clockwise - When viewed looking into the input shaft
Front and rear displacments
35 cm³ (2.1 in³)
Manual swashplate displacement control
19.05 mm (0.75 in) square input shaft
Charge pressure relief setting
24 - 25 bar (348 - 363 psi) @ 1800 RPM
System pressure relief setting
345 bar (5003 psi) +5 / 0 %
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Combination pump
Direction of Rotation
Clockwise
Nominal displacement
46 cm³ (2.8 in³)
Maximum displacement port A
46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)
Maximum displacement port B
46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)
Shaft test speed
2000 RPM
Charge pressure
25 bar (363 psi +/- ) 1.0 bar (15 psi)
Relief valve A
385 bar (5583 psi +/- ) 10 bar (145 psi)
Differential pressure A
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Relief valve B
385 bar (5582 psi +/- ) 10 bar (145 psi)
Differential pressure B
360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)
Nominal voltage
12 V
Port
(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 53cc hydrostatic pump, used with large frame models. SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Manufacturer
Rexroth
Type
Piston pump
Direction of Rotation
Clockwise
Nominal displacement
63 cm³ (3.8 in³)
Test speed
2800 RPM
Charge pressure
25 bar (363 psi)
Relief valve A
276 bar (4002 psi)
Differential pressure A
241 bar (3495 psi)
Relief valve B
207 bar (3002 psi)
Differential pressure B
182 bar (2639 psi)
Nominal voltage
12 V
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Manufacturer
Sauer-Danfoss
Type
Pump-Tandem
Direction of Rotation
Clockwise
Front and rear displacments
46 cm³ (2.8 in³)
Bushed block rotating speed
up to 3600 RPM
Manual displacement control
Mechanical input, servo actuated with swashplate position feedback
Charge pump flow
30.3 l/min (8 US gpm) at 1800 RPMwith 48.9 °C (120 °F) oil
Charge pressure relief setting
24 - 25 bar (348 - 363 psi) @ 1800 RPM with 48.9 °C (120 °F) oil
System pressure relief setting
360 bar (5220 psi) +5 % set at 4.5 - 4.9 l/min (1.2 - 1.3 US gpm) with 48.9 °C (120 °F) oil
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models SR130, SR150, SR175, SV185
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
325 cm³/rev (20 in³/rev)
Speed
Maximum Operating: 330 RPM
Maximum Operating Pressure
System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Motor - General specification for mechanical 470cc single speed motor on medium and large frames SR200, SR220, SR250, SV250, SV300
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
470 cm³/rev (28.7 in³/rev)
Speed
Maximum Operating: 385 RPM
System Operating Pressure
Differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Motor - General specification for 325cc 2 speed motor on medium frames SR175, SV185, SR200
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
325 - 200 cm³/rev (19.8 - 12.2 in³/rev).
Speed
Maximum Operating: 330 RPM, 430 RPM at minimum displacement.
Output Shaft
10 Tooth RC 80 Sprocket
Maximum Operating Pressure
System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Displacement Shift Pressure
15 bar (218 psi) maximum.
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames SR200, SR220, SR250, SV300
Manufacturer
Bosch-Rexroth
Type
Direct drive radial piston motor
Direction of Rotation
Bi-directional
Displacement
470 - 282 cm³/rev (28.7 - 17.2 in³/rev).
Speed
Maximum Operating: 385 RPM, 465 RPM at minimum displacement.
Output Shaft
9 Tooth RC 100 Sprocket
Maximum Operating Pressure
414 bar (6000 psi) System operating differential relief pressure 345 bar (5003 psi).
Brake Release
11 - 15 bar (160 - 218 psi)
Displacement Shift Pressure
15 bar (218 psi) maximum.
Ports
Main Ports: A and B Case Drain Port: L Brake Release Port: Z
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Motor - General specification for track drive 2 speed motor on medium and large frames TR270, TR320, TV380
Manufacturer Type Direction of Rotation Displacement Speed Maximum Operating Pressure Brake Release Displacement Shift Pressure Ports
Bonfiglioli Radial or Axial piston with planetary reducer Dual rotation Two speed 50.9 - 33.1 cm³/rev (3.1 - 2.0 in³/rev) with 21.58:1 output reducer. Maximum Operating: 106 RPM in low range. 162 RPM in high range. 241 bar (3500 psi) Maximum differential relief pressure 345 bar (5003 psi). Fully released at 13 bar (189 psi). Maximum allowable brake pressure 49 bar (711 psi) 15 bar (218 psi) maximum. Service Ports: P1 and P2 2 Speed Control Port: Ps Drain Port: Dr
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - Overview Hydrostatic pump model identification The skid steer product line is very versatile and comes with many options. The information below is to help with understanding what hydrostatic pumps may be equipped with certain models. Model SR130
Controls Mechanical Electro-hydraulic
SR150
Mechanical Electro-hydraulic
SR175
Mechanical Electro-hydraulic
SV185
Mechanical Electro-hydraulic
SR200
Mechanical Electro-hydraulic
SR220
Mechanical Electro-hydraulic
SR250
Mechanical
Electro-hydraulic
SV250
Mechanical Electro-hydraulic
SV300
Mechanical
Electro-hydraulic
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Hydrostatic Pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Model TR270
Controls Mechanical Electro-hydraulic
TR320
Mechanical
Electro-hydraulic TV380
Mechanical
Electro-hydraulic
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Hydrostatic Pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
TRANSMISSION Hydrostatic - Cleaning The hydrostatic system is a closed loop made up of the charging pump, piston pump, drive motors and the hoses between these components. The hydraulic cooler and reservoir are also part of the closed loop system. Any contamination in the hydrostatic system will stay in the closed loop, and probably cause damage. If the piston pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1.
Remove the piston pumps and at least the motor in the circuit that failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required.
2.
Disassemble, clean, and inspect the piston pumps and motor(s).
3.
Clean all hoses and tubes in the hydrostatic system. Remove each hose and tube from the machine. Flush and clean the hoses and tubes with hot soapy water. Hang and allow them to air dry. Hoses and tubes must be dry before installing.
4.
Install, inspected and repaired, or new piston pumps and motors.
5.
Change the hydraulic filter.
6.
Make sure that the hydraulic system is clean so that the charge pump will not cause new contamination in the closed loop. Remember that the oil cooler may have internal passages that can trap and hold contamination that can be dislodged later and cause a repeat failure.
NOTE: THE FOLLOWING PROCEDURE SHOULD BE USED FOR CLEANING HOSES, TUBES, AND FITTINGS. It is recommended that hoses, tubes and fittings be cleaned with a steam cleaner and dried with compressed air. 7.
Fasten the parts to a rack in a position as near to vertical as possible. This will allow water to drain as you flush parts.
8.
Clean the exterior surfaces of the parts thoroughly.
9.
Clean the interior surfaces of the parts. Use hot water and soap first. Then use clean hot water to rinse.
NOTE: If the steam cleaner does not have a soap injection system, spray an oil solvent into the parts. This will dissolve the oil film that holds contaminants inside the parts. Then use clean hot water to rinse. 10.
Fasten the parts in the rack so that the parts can be flushed from opposite ends. Repeat steps 8 an 9.
11.
Use compressed air to dry the inside of each part. Dry the parts from both ends to make sure all of the water is removed.
12.
Install caps or plugs in the ends of each hose, tube or fitting as soon as the parts are dry. This will prevent entry of contaminants. Remove the caps or plugs from the part only when the part is in position in the machine and you are ready to make the connection.
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Command - Remove Right hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A) NOTE: This procedure covers how to remove the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
3.
4.
Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
Locate the drive solenoid that needs to be removed. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of the hydrostatic pump.
Disconnect the connector (2) from the solenoid. Unscrew the cap (1).
Slide the solenoid off.
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Command - Install Right hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: This procedure covers how to install the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
Place the solenoid on to the valve body. See picture for location of solenoids. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of hydrostatic pump.
931001814
1
931001814
2
Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Command - Remove Left hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A) NOTE: This procedure covers how to remove the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
3.
4.
Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
Locate the drive solenoid that needs to be removed. The left hand forward (1) and left hand reverse (2) solenoids are located near the auxiliary pump.
Disconnect the connector (1) from the solenoid. Unscrew the cap (2).
Slide the solenoid off.
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Command - Install Left hand drive solenoid(s) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: This procedure covers how to install the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.
2.
Place the solenoid on to the valve body. See picture for location of solenoids. The left hand reverse (1) and left hand forward (2) solenoids are located near the auxiliary pump.
931001814
1
931001814
2
Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Relief valve - Pressure test Ground Drive Relief Valve - Manual control models SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Test Procedure: 1.
Raise and securely block the unit off the ground.
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 2.
3.
4.
Remove the brake release line from the tee fitting that connects to the B port (1) of the brake valve (2).
931002074
1
931002074
2
Cap the tee fitting that connects to the B port (1) of the brake valve (2).
Connect a 690 bar (10,000 psi) pressure gauge to the high pressure loop gauge port. See the illustration below.
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HI01E019
3
Sauer M46 (1) Right Hand motor reverse test port, (2) Right Hand forward test port, (3) Left Hand motor test port, (4) Left Hand reverse test port
93111529
4
Sauer M35 right side view (1) front service line port, (2) rear service line port
93111523
5
Sauer M35 top view (1) front service line port, (2) rear service line port (opposite side bottom) 5.
Lower the cab and route the pressure gauge so that it can be viewed while running the unit from the operator’s seat. Start the unit and disengage interlocks to operate unit.
NOTE: An error will appear on the Instrument Cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 6.
If the hydraulic oil is not at operating temperature, run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 5 seconds. Then return the bucket control lever to NEUTRAL for 5 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).
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7.
Increase the engine speed to full throttle. Move the control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the control lever to NEUTRAL.
8.
The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the illustration below.
HI01E019_2
6
Sauer M46
93111523
7
Sauer M35 top view (1) bypass relief valves, (2) bypass relief valves (opposite side bottom)
93111529
8
Sauer M35 right side view (1) charge pressure relief valve 9.
Reconnect the brake lines to their original state.
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Relief valve - Pressure test (Machines Equipped with EH Controls) SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 1.
Connect a 68 947 kPa (690 bar) (10,000 psi) pressure gauges to the test ports MA (1) and MB (2). See the figure below.
NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. NOTE: You will need two people to perform this test. The operator seat must be in the raised position to gain access to the hydrostatic pump. This test can be done in either ISO or H pattern. H pattern in preferred, only one pump will be actuated at a time.
20111250
2.
Connect a 4137 kPa (41.4 bar) gauge in the Yst port located on the top center of pump.
3.
Remove brake release lines from B port of the brake valve, plug lines and cap fittings in B port.
4.
If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).
5.
Run the engine at low idle. Move the ground drive control lever slowly to the FORWARD position.
6.
Increase the engine speed to full throttle. Slowly move the ground drive control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the ground drive control lever to NEUTRAL.
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7.
The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the figure below.
20111248
(1)Right Hand Forward Drive Circuit Relief Valve (2) Right Hand Reverse Drive Circuit Relief Valve
(3) Left Hand Forward Drive Circuit Relief Valve (4) Left Hand Reverse Drive Circuit Relief Valve
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Pressure release valve - Remove High pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Prior operation: To depressurize the system, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
Locate the high pressure relief valve(s) (1).
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2.
Remove the high pressure relief valve(s) (1).
20115785
Next operation: Pressure release valve - Install High pressure relief (C.20.F).
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Pressure release valve - Install High pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Lubricate the threads (1) and support surface (2).
20115785
1
20115485
2
Thread the high pressure relief valve(s) (1) into the pump housing. Torque to 250 N·m (184.4 lb ft).
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Pressure release valve - Remove Low pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Prior operation: To depressurize the system, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
2.
Locate the low pressure relief valve (1).
20115485
1
20115786
2
Remove the low pressure relief valve (1).
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3.
4.
Remove the spring collar (1).
83115530
3
83115531
4
Remove the pressure spring (1).
Next operation: Pressure release valve - Install Low pressure relief (C.20.F).
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Pressure release valve - Install Low pressure relief SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Place the collar (1) and pressure spring (2) onto the low pressure relief valve.
20115786
1
20115485
2
Thread the low pressure relief valve (1) into the pump housing. Torque to 70 N·m (51.6 lb ft).
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Pump - Adjust Servo Piston Centering Spring SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: If more than one full turn of the servo adjusting screw was required when performing Pump - Travel adjust (C.20.F), or if the machine has the tendency to continue traveling in the direction that it was going last, both forward and reverse, check and adjust the locking nut on the adjusting screw at the servo piston centering spring. The only way for this nut to change adjustment, is if the internal centering spring should break, the spring retainer snap ring fails or the lock nut becomes loose. 1.
Remove the cap and external sealing nut (1).
2.
Remove the bolts retaining the servo piston cover in place.
3.
Rotate the piston cover off of the servo adjusting screw.
4.
Tighten or loosen the centering spring lock nut (2) until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
5.
Install the piston end covers and bolts.
6.
Perform Pump - Travel adjust (Stopping machine creep) (C.20.F) to center the servo piston.
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Pump - Travel adjust (Stopping machine creep) SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pump Adjustments Stopping Machine Creep 1.
In order to correct a creeping hydrostatic drive, a systematic diagnosis procedure must be followed. First, determine if it is the pump’s fault by disconnecting the control linkage to the servo control levers on the pump. If the problem disappears, inspect the linkage and correct the problem. Improper rod length, binding control bushings, binding control cables, etc., are some common problems. If after disconnecting the linkage, the system still moves, pump adjustments are available to correct the problem. If the only operational symptom noted is that one or both drive systems continue to move with the controls in neutral, adjustment of the servo control valve may possibly be all that is required (See Pump - Adjust Hydraulic Neutral (C.20.F)). If the unit does not track in a straight line or if one side tends to continue in the direction that it was going last, it is recommended to adjust the servo piston centering mechanism before adjusting the hydraulic neutral control.
Centering the Servo Piston 2.
The servo control piston has a very strong spring centering mechanism to return the pump to neutral condition when the hydraulic servo control is in neutral. A control rod from the centering mechanism runs through one end cover to allow for external adjustment. Use the following procedure to center the pilot servo piston:
NOTE: You will need two people to perform this procedure. NOTICE: The machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. 3.
Raise and secure block the unit off the ground.
NOTE: Never disconnect a hydraulic hose without depressurize the system, see PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). 4.
Disconnect and cap the charge pressure supply line (from the brake release solenoid valve) to the servo control inlet line. This is a small steel line that runs in between the two servos. This will allow you to adjust both pumps without hydraulic interference to the mechanical adjust you are performing.
931001966
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5.
Start the engine and run at full throttle.
6.
Loosen the jam nut and turn the servo adjusting screw in one direction until the tires just begin rotate, note the position of the adjusting screw. Turn the adjusting screw in the opposite direction until the tires just begin to rotate in the opposite direction, note the position of the screw. Repeat these steps again to verify the position of the screw when the tires begin to rotate. Center the adjusting screw between both positions and tighten the lock nut. NOTE: if more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted (see servo centering spring adjustment).
NOTE: If more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted. Perform Pump - Adjust Servo Piston Centering Spring (C.20.F). 7.
If the other pump requires adjustment, repeat Step 6 on the other pump.
8.
Stop the engine.
9.
Uncap and reconnect the charge pressure supply line
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Pump - Adjust Hydraulic Neutral SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Raise and secure block the unit off the ground.
2.
Start and run the engine at full throttle.
3.
Loosen the lock bolt for the servo control adjustment bracket. Move the bracket in one direction until the tires just begin to rotate in one direction and mark the position of the bracket. Move the bracket in the opposite direction until the tires just begin to rotate in opposite direction and mark the position of the bracket. Repeat the above steps to assure that the proper bracket position was marked. Center the adjustment bracket between the marks and tighten the lock bolt. Securely hold the bracket in position when tightening the lock bolt to prevent movement caused by the bolt head.
4.
After the bracket has been secured in position, gradually move the pump control lever away from the centered position in both directions. The servo control adjustment bracket is properly adjusted when an even amount of lever travel is required to begin tire rotation in both directions. Readjust as necessary to attain the centered position.
5.
If the other pump requires adjustment, repeat Steps 3 and 4 on the other pump.
6.
Stop the engine.
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Pump - Adjust EH Servo Piston Centering Spring SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
WARNING Crushing hazard! Before performing service under the machine, park the machine on a level surface, engage the parking brake, and stop the engine. Put blocks at the front and rear of the tires. Failure to comply could result in death or serious injury. W0350A
NOTE: Creep adjustments for the EH unit are less involved due to there being no linkage or hydraulic neutral adjustments. The procedure below is used to reduce drive creep in a electro-hydraulic machine. After checking charge pressure to confirm they are in spec there is only one adjustment, the centering of the servo piston. The procedure is very similar to a mechanical machine. 1.
Raise and securely block the unit off of the ground.
2.
Depressurize the system, PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) Deactivate the hydraulic servo control spool for the pump to be adjusted by disconnecting and capping the pressure supply hose (1). This completely takes the hydraulic control out of the servo and allows for a mechanical adjustment.
3.
Start the engine and run the engine at full throttle.
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1
931001814
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
4.
Tighten or loosen the centering spring lock nut until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
NOTE: If more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted. See step 5. 5.
Remove the cap and external sealing nut (1).
6.
Remove the bolts retaining the servo piston cover in place.
7.
Rotate the piston cover off of the servo adjusting screw.
8.
Tighten or loosen the centering spring lock nut (2) until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.
9.
Install the piston end covers and bolts.
10.
Repeat steps as needed, if other pump requires adjustment.
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3
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - Remove mechanical hydrostatic pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A) NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 1.
2.
3.
Label and disconnect the four left hand side hydraulic hoses (1) and cap open ports
931002072
1
931002073
2
931002074
3
Label and disconnect the gear pump hydraulic tube (1) and supply hose (2) and cap open ports.
Label and disconnect right hand side hydraulic hoses (1) and cap open ports
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4.
5.
6.
7.
Disconnect control linkage hardware (1).
931002075
4
931002076
5
931002077
6
931002078
7
Disconnect electrical connection (1).
Using a metal rod as a brace across the pump attach lifting straps and hoist to support pump, as shown.
Remove the four pump mounting bolts (1) and (2).
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8.
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Using the hoist carefully remove pumps. 931002079
Next operation: Pump - Install mechanical hydrostatic pump (C.20.F)
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Pump - Install mechanical hydrostatic pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Pump - Remove mechanical hydrostatic pump (C.20.F) 1.
Before pump installation, apply MOLYKOTE® G-N METAL ASSEMBLY PASTE or CASE AKCELA MOLY GREASE to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil.
2.
Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines at the rear of the hydrostatic pump. After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.
3.
931002077
1
931002078
2
Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts (1) into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft). Apply LOCTITE® 243 to pump support bracket bolts (2). Install washer on bolts and install bolts. Tighten the pump support bracket bolts 55 - 60 N·m (40.6 - 44.3 lb ft).
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4.
5.
6.
7.
Connect electrical connection (1).
931002076
3
931002075
4
931002074
5
931002073
6
Connect control linkage (1).
Connect the right hand side hydraulic hoses (1).
Connect the rear hydraulic tube (1) and supply hose (2).
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8.
Connect the four left hand side hydraulic hoses (1) to the correct ports.
931002072
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Pump - Remove EH hydrostatic pump SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt system - Tilt (E.34.A) Oil cooler - Remove (A.10.A) 1.
Label and disconnect control wires (1) on bottom of pumps
931001961
1
NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic system. 2.
Label and disconnect the two front (1) and two rear (2) pump control connections.
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3.
4.
5.
6.
Label and disconnect the hydraulic oil temperature sender (1).
931001963
3
931001964
4
931001965
5
931001966
6
Label and disconnect the right hand side hydraulic hose (1).
Label and disconnect the oil supply hose (1) by loosening the hose clamp and cap ports.
Label and disconnect the top hydraulic tube (1) and cap open ports.
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7.
8.
9.
10.
Label and disconnect right hand side drive motor hoses (1) and cap open ports.
931001970
7
931001971
8
931001972
9
Label and disconnect left hand side drive motor hoses (1) and cap open ports.
Label and disconnect hydraulic hose (1) and cap open ports.
Label and disconnect case drain hose (1) and cap open ports.
931001963
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11.
12.
13.
Label and disconnect gear pump supply hose (1) and cap open ports.
931001955
11
931001956
12
931001974
13
931001928
14
Label and disconnect gear pump hydraulic tubes (1) and cap open ports.
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Place a lifting strap around the pump and using a hoist support the pump, as shown. 14.
Remove the two mounting bolts and washers (1) from the pump.
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15.
Using the hoist, carefully remove pumps.
931001976
Next operation: Pump - Install EH hydrostatic pump (C.20.F)
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Pump - Install EH hydrostatic pump SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
Prior operation: Pump - Remove EH hydrostatic pump (C.20.F) NOTE: Before pump installation, apply CASE AKCELA MOLY GREASE to the pump and the coupling splines. Mount coupling star (1) to pump shaft with supplier logo facing out, toward the engine. Set coupling to dimension shown in the image below. Torque set screws to 25.7 - 28.3 N·m (19.0 - 20.9 lb ft) . Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 1.
2.
3.
Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines (1) at the rear of the hydrostatic pump. The distance (X) should be 49 mm (1.9 in) . After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.
93111555A
1
931001928
2
931001956
3
Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft).
Connect gear pump hydraulic hoses (1) as shown.
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4.
5.
6.
7.
Connect the gear pump supply hose (1) and tighten hose clamp.
931001955
4
931001963
5
931001972
6
931001971
7
Connect case drain hose (1) and secure with clamp.
Connect hydraulic hose (1), as shown.
Connect left hand side drive motor hoses (1).
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8.
9.
10.
11.
Connect right hand side motor hoses (1).
931001970
8
931001966
9
Connect the top hydraulic hose (1).
Connect the oil supply hose (1) and tighten hose clamp.
931001965
10
931001964
11
Connect right hand side hydraulic hose (1).
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12.
13.
14.
Connect hydraulic oil temperature sender (1) and secure with nut.
931001963
12
20111248
13
931001961
14
Connect the front (1) and rear pump control connections (2).
Connect the sensor wires (1) located on the bottom of pumps.
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Pump - Install Gear pump NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1.
2.
Install gear pump (1) and retaining bolts (2). Tighten bolts to torque.
931002073
1
931002073
2
931001955
3
Connect gear pump hydraulic tube (1).
NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, connect second hydraulic tube.
3.
Connect gear pump supply hose (1).
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Pump - Remove Gear pump WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A
Prior operation: For depressurizing the hydraulics, refer to PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A). NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1.
2.
Label and disconnect gear pump supply hose (1). Cap open ports.
931001955
1
931002073
2
931002073
3
Label and disconnect gear pump hydraulic tube (1). Cap open ports.
NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, label and remove second hydraulic tube. Cap open ports.
3.
Remove the gear pump retaining bolts (1). Remove gear pump.
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Pump - Disassemble Hydrostatic pump unit disassemble SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Some types of failures will require the disassembly of the tandem pump for cleaning and inspection. If there is failure in the drive motors or tandem pump, disassemble both the rear and front pumps, the drive motors, and all hoses between the pumps and drive motors. 1.
2.
3.
Remove the bolts that fasten the pumps together.
83111565
1
83111566
2
83111567
3
Remove the nut and bracket from the stud.
Separate the pumps (1).
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4.
Remove the two O-rings (1) and back-up ring (2).
83111568
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump - Assemble Hydrostatic pump unit assemble SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
2.
3.
4.
Install new O-rings and back-up ring.
83111568
1
83111567
2
83111566
3
83111565
4
Install bracket and nut. Connect the front and rear pump together.
Torque the retaining nut to 102 N·m (75.2 lb ft)
Install the bolts that fasten the front and rear pumps together. Torque the bolts to 91 - 111 Nm ( 67 - 82 lb ft
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Pump - Disassemble Sauer Danfoss 35cc mechanical pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Separate the pumps by removing the left and right side pump mounting bolts (1).
20115788A
1
20105293N
2
20115791
3
Remove the coupling (1) and gerotor (2) assembly from the gerotor cover.
Note the orientation of the gerotor assembly (1) and pins (2) for reassembly into housing (3).
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4.
5.
6.
Remove pin (1) from the coupler. For inspection of the charge pump, refer to Charge pump - Inspect (C.20.F).
20115790
4
20115820
5
83115796
6
Remove the end cap mounting bolts (1) from the pump housing (2). Discard the gasket.
Remove the valve plate.
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7.
8.
9.
10.
Remove circuit relief valve (1) from both sides of end cap.
20115795
7
20115825
8
20115794
9
Remove charge relief plug (1).
Remove the needle bearing.
Remove cylinder and piston assembly.
83115797
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10
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11.
12.
13.
14.
Remove the thrust plate.
20115826
11
83115799
12
83115801
13
83115798
14
Remove pistons and guide.
Remove the retainer guide, washer, pins and pin retainer.
Install a bolt with two washers to compress the spring.
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15.
16.
17.
Remove retaining ring. Release the spring. Remove the spring seats and spring
83115800
15
20115787
16
83115802
17
Remove the snap ring (1).
Remove seal and retainer.
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18.
19.
20.
21.
Discard o-ring and seal.
83115804
18
83115806
19
83115803
20
20105288N
21
Remove drive shaft and bearing.
Remove snap ring and bearing from drive shaft.
Remove trunnion cover (1).
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22.
23.
Remove top trunnion cover bolts (1) and cover.
20115822
22
83115809
23
Remove swashplate and bearing.
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Pump - Assemble Sauer Danfoss 35cc mechanical pump SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Install a new seal in trunnion cap. Seal lip goes to inside.
83115810
1
83115811
2
83115812
3
Install bearing cone on the swash plate.
Install swash plate. Shaft comes out the side of housing nearest the serial number plate.
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4.
5.
6.
7.
Install the bearing, original shims, spacers, a new quad ring and blank trunnion cover.
83115805
4
83115807
5
20115822
6
20115829
7
Install the bearing cup, original shims, spacer, and new quad ring.
Install the trunnion cover. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft)
Remove approximately 0.1 mm (0.005 in) of shims from each of the trunnion shim packs. Assemble the trunnion assemblies with the reduced shim packs. Tighten the bolts to a torque of 24.4 - 32.5 N·m (18 - 24 lb ft). Move the control arm up and down while measuring the end play with a dial indicator. Add shims to provide a 0.1 - 0.1 mm (0.002 - 0.004 in) preload on the swash plate bearings. Add shims equally on each side of pump housing. The swash plate should move freely with a torque of 0.6 - 1.7 N·m (5 - 15 lb in) applied to the control arm.
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8.
9.
10.
Install the bearing and snap ring on the drive shaft. Install the drive shaft and bearing into the housing.
83115806
8
83115804
9
Install a new seal and o-ring in the seal retainer. Install the seal retainer and snap ring.
Install the thrust plate.
20115826
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10
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
11.
12.
13.
Install the inner spring seat, spring and outer spring seat into the cylinder. Compress the spring with the bolt and washers and install the retaining ring.
83115800
11
83115798
12
83115801
13
83115799
14
Install the pin retainer flush with top of cylinder. Install the pins in the recesses of the splines. Install the washer then retainer guided on top of the pins.
Install the pistons in the slipper guide. Lubricate the pistons and cylinder block bores. Install the pistons into the cylinder block.
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14.
15.
16.
17.
Install the cylinder assembly into the housing. Turn the shaft to help align the splines. The cylinder must go into the housing until the slippers contact he thrust plate.
83115797
15
20115794
16
20115795
17
20115825
18
Install the needle bearing so 2.0 - 2.5 mm (0.08 - 0.1 in) protrudes above the end cap surface. Printed end of bearing cage must face up.
Install the two circuit relief valves, springs and plugs with new o-rings. Both relief valves are the same. Tighten to a torque of 40.7 - 67.8 N·m (30 - 50 lb ft).
Install the charge relief valve, shims, spring and poppet into the housing with a new o-ring. Tighten to a torque of 54.2 - 135.6 N·m (40 - 100 lb ft).
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18.
19.
20.
Install the valve plate on the end cap with the brass side toward the pump cylinder. The cut out notch on OD locates on the roll pin in the end cap. Do not interchange valve plates. RH Drive Pump valve plate (1), LH Drive Pump valve plate (2)
83115796
19
20115821
20
83115813
21
20105293N
22
Install the end cap with a new gasket. Tighten the socket head screws to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Rotate the shaft to assure correct assembly. When properly assembled, a torque of 2.3 - 5.7 N·m (1.7 - 4.2 lb ft) should be required to turn the shaft.
Install the coupling on the shaft. Assemble the two piston pumps using new o-rings.
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21.
Tighten the socket head screws (1) to a torque of 47.5 - 61.0 N·m (35 - 45 lb ft). Check for proper internal assembly by slowly rotating the pump shaft while tightening these screws.
20115788A
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23
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
Pump Right hand pump - Disassemble Hydrostatic pump Sauer Danfoss 46cc SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. Left side pump disassembly is the same. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Remove the charge pump cover. Note the position of the charge pump cover pin (1) for use during assembly.
83111569
1
83111570
2
83111571
3
Remove the coupling from the inner gear.
Remove the inner gear from the outer gear.
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4.
5.
6.
7.
Remove the outer gear from the charge pump cover.
83111572
4
83111573
5
83111574
6
83111575
7
Remove the bolt stud.
Remove the special bolts from the cover.
Remove the cover, the gasket, and the shaft assembly.
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8.
9.
10.
11.
Remove the swash plate.
83111576
8
83111577
9
Remove the retainer and the pistons.
Remove the guide.
83111578
10
83111579
11
Remove the cylinder block.
NOTE: Do not disassemble the cylinder block.
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12.
13.
14.
15.
Do not lose the three pins (1) that are inserted into the cylinder block. They must stay in position.
83111580
12
83111581
13
83111582
14
83111583
15
Remove the wear plate.
Remove the gasket.
Remove the snap ring from the seal.
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16.
17.
18.
19.
Fasten the cover in a vise with soft jaws. Use a prybar to remove the seal.
83111584
16
83111585
17
83111586
18
83111587
19
Remove the snap ring from the groove, just above the ball bearing.
Push the shaft out of the cover. Inspect the bearing on the shaft. Replace if necessary.
Inspect the bearings (1) on the cover. If the tan surface has worn through to the dark base, use new bearings.
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20.
21.
22.
23.
Remove the screws from the cover.
83111588
20
83111589
21
83111590
22
83111591
23
Pull out the piston assembly from the housing.
Remove and discard the gasket.
Fasten the piston assembly in a vise with soft jaws. Hold the special bolt in place. Remove the special nut. Ensure that the special bolt does not turn while removing the special nut.
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24.
Measure the distance between the top of the special bolt and the cover. Record that measurement.
25.
Thread the cover counterclockwise until it is removed from the special bolt.
26.
Fasten the piston in a vise with soft jaws. Hold the adjusting nut in place. Loosen the jam nut.
27.
28.
83111592
24
83111593
25
83111594
26
83111595
27
Hold the special bolt in place. Tighten the adjusting nut to push the outer spring guide down, and away from the retaining ring.
Remove the retaining ring.
NOTE: The retaining ring will be difficult to remove.
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29.
30.
31.
32.
Hold onto the end of the special bolt and pull out the spring assembly.
83111596
28
83111597
29
83111598
30
83111599
31
Thread the jam nut (1) and the adjusting nut (2) counterclockwise until they are removed from the special bolt. Separate the outer spring guide (3), spring (4), sleeve, and inner spring guide (5) from the special bolt.
Remove the piston from the housing. Remove and discard the O-rings, and the piston rings from each end of the piston (1).
Remove the screws from the cover.
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33.
34.
35.
36.
Remove the cover and discard the gasket.
83111600
32
83111601
33
83111602
34
83111603A
35
Go to the spool assembly. Mark the position of where the stop bracket is bolted. Repeat for the other side.
Remove the bolts and the spool assembly from the housing.
Remove the sleeve from the housing.
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37.
38.
39.
40.
Remove the lock nut and washer from the spool.
83111604
36
83111605
37
83111606
38
83111607
39
Remove and discard the backup ring (1) and O-ring (2) from the spool.
Remove and discard the backup ring (1) and O-ring (2) from the sleeve.
Remove the hex plug and shims for the charge pressure relief valve.
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41.
42.
43.
44.
Remove the shims from the hex plug. Save the shims for later use.
83111608
40
83111609
41
83111610
42
83111611
43
Remove the spring.
Remove the valve poppet with a slide hammer.
Mark the hex plug that is used for the circuit reliefcheck valve.
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45.
46.
47.
48.
Remove the hex plug.
83445485
44
83111612A
45
83111613A
46
83111614B
47
Remove the spring.
Remove the circuit relief-check valve.
Loosen the bypass valve.
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49.
50.
51.
Thread the bypass valve counterclockwise until it is removed.
83111615C
48
83115460
49
83115461
50
Remove and discard the O-ring (1) and backup ring (2).
Remove the plug.
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Pump Right hand pump - Visual inspection Hydrostatic pump visual inspection SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. 1.
Inspect the face of the cylinder block for wear, scoring, and other damage. Use a new cylinder assembly as necessary.
2.
Inspect the cylinder bores for wear, scoring, and other damage. Use new cylinder assembly as necessary.
3.
Inspect the bronze surface of the wear plate. Use a new wear plate as necessary.
4.
Inspect the parts of the charging pump for wear and damage. Use a new pump as necessary.
5.
Inspect the pistons for wear and damage, use new parts as necessary.
6.
Inspect the shaft for damage to the splines and wear at the seal surfaces.
7.
Inspect the bearings. Replace any damaged bearings.
8.
Inspect the circular relief valve seats in the housings.
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Pump Right hand pump - Measure Hydrostatic pump - measure SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. 1.
2.
Measure the free travel between the shoes and the pistons. If all the measurements are not equal to within 0.13 mm ( 0.005 in), use a new cylinder assembly.
83115462
1
83115463
2
Measure the thickness of each shoe. If the measurements are not equal to within 0.02 mm ( 0.0001 in), use a new cylinder assembly.
3.
Check the fit of the pistons in the bores. The piston must move freely with minimum clearance. Use a new cylinder assembly as necessary.
4.
Measure the gear tip clearance between the inner gear and the outer gear. Clearance must not be more than 0.13 mm ( 0.005 in).
5.
Measure the width of the inner gear and the outer gear. The width of each gear must be equal to within 0.05 - 0.06 mm ( 0.002 - 0.003 in).
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Pump Right hand pump - Assemble Hydrostatic pump assemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
NOTE: This procedure is for all M46 Sauer Danfoss hydrostatic pumps. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1.
2.
3.
Install the plug. Tighten the plug to a torque of 0.9 1.3 Nm (8 - 12 lb in).
83115461Z
1
83115460Z
2
83111615L
3
Slide a new backup ring (2) and O-ring (1) into the grooves of the bypass valve.
Thread the bypass valve into the housing.
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4.
5.
6.
7.
Tighten the bypass valve to a torque of 9 - 13 Nm (84 - 120 lb in)
83111614Q
4
83111613H
5
83111612T
6
83445485V
7
Thread the circuit relief-check valve into the housing.
Insert the spring on top of the circuit relief-check valve.
Thread the plug on top of the spring. Tighten the plug to a torque of 115 - 230 Nm ( 85 - 170 lb ft).
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8.
9.
10.
11.
Use a slide hammer to insert the valve poppet into the housing for the charge pressure relief valve.
83111610T
8
83111609S
9
Insert the spring on top of the valve poppet.
Insert the necessary quantity of shims into the hex plug. Thread the hex plug on top of the spring. Tighten but do not overtighten.
83111607-
10
83111606H
11
Slide a new O-ring (2) and backup ring (1) into the grooves of the sleeve.
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12.
13.
14.
15.
Slide a new O-ring (2) and backup ring (1) into the grooves of the spool.
83111605S
12
83115464G
13
83111604P
14
83111603PNA55
15
Insert the spool into and through the stop bracket. Refer to the alignment mark made during disassembly Pump Right hand pump - Disassemble (C.20.F).
Slide the washer and nut onto the protruding threads of the spool. Hold the spool assembly in place. Tighten the nut, but do not overtighten.
Lubricate the sleeve. Insert the sleeve into the housing. Ensure that the notch on the end of the sleeve is properly aligned with the notch inside housing.
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16.
17.
18.
19.
Lubricate the spool. sleeve.
Insert the spool inside the
83115465H0
16
83111602AS
17
83111600HJ
18
83111599FUG
19
Refer to the alignment mark made during disassembly Pump Right hand pump - Disassemble (C.20.F). Ensure the marks are in alignment. Secure the spool assembly with two bolts.
Place the new gasket and cover onto the rim of the housing.
Secure the cover with screws.
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20.
21.
22.
23.
Slide the inner spring guide (5), sleeve, spring (4), outer spring guide (3), the adjusting nut (2), and the jam nut (1) onto the special bolt.
83111597I
20
83115466GH
21
83111598P
22
83111596RQWE
23
Hold the bolt assembly in place. Tighten the adjusting nut to begin compression of the spring.
Insert one new ring (2) and one O-ring (1) into the grooves on each end of the piston.
Fasten the piston in a vise with soft jaws. Hold onto the end of the of the special bolt to insert the spring assembly into the piston.
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24.
25.
26.
27.
Hold the special bolt in place. Tighten the adjusting nut until the outer spring guide is below the groove. This will allow space for the retaining ring.
83111594FHJ
24
83115467DB
25
83111594G
26
83115468KIJ
27
Install the retaining ring onto the spring assembly.
Slightly loosen the special bolt. Ensure that the spring and adjusting nut do not become loose.
Hold the adjusting nut and special bolt in place. Tighten the jam nut. Recheck the special bolt and spring. Verify that the spring did not become loose.
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28.
29.
30.
31.
Lubricate the piston with clean oil. Slide the piston into the housing.
83115469HY
28
83115470TRY
29
83115471GH
30
83111588SD
31
Slide a new gasket and cover onto the special bolt.
During disassembly, the measured distance between the top of the special bolt and cover was recorded. Pump Right hand pump - Disassemble (C.20.F). Thread the cover up or down the special bolt until the distance is equal to that recorded measurement.
Secure the cover with four screws. Tighten the screws to the torque of 11 - 15 Nm ( 96 - 132 lb in).
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32.
33.
Hold the special bolt in place. Slide the special nut (with the sealing surface side down) onto the special bolt. Tighten the special nut, but do not overtighten.
83115472DFH
32
83115473MIO
33
83115474KO
34
83115475DR
35
During disassembly, the bearings on the cover were inspected Pump Right hand pump - Disassemble (C.20.F). If one of the bearings need to be replaced, align and insert the cover roll pin into the hole of the bearing. This will ensure proper placement.
NOTE: If a new cover is being used, install new roll pins so the distance between the tops of the roll pins and the face cover are 2.3 - 2.8 mm ( 0.090 - 0.110 in).
34.
35.
During disassembly, the ball bearing for the shaft was inspected Pump Right hand pump - Disassemble (C.20.F). If the ball bearing for the shaft has been replaced, install one snap ring on each side of the ball bearing.
Fasten the cover in a vice with soft jaws. Firmly press the ball bearing and the shaft into the cover.
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36.
37.
38.
39.
Install the snap ring into the groove, just above the ball bearing.
83111585DFDFHFH
36
83115476ASDFG
37
83111583F
38
83111581DFF
39
Lubricate the lip of the seal with clean oil. Carefully press the new seal with the lip down, into the cover.
Install the snap ring into the seal.
Lubricate the wear plate with clean oil. Align the notch on the wear plate with the roll pin that is located inside the cylinder port. Insert the wear plate with the bronze surface side up, into the cylinder port.
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40.
41.
42.
43.
Ensure that the three pins are still inserted in the cylinder block.
83111580DFFG
40
83115477WEED
41
83111579CVBNJ
42
83115480SDF
43
Hook the retaining collar and slide it up the splines until it reaches the top.
Insert the cylinder block into the pump.
Align and install the guide on top of the pins.
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44.
45.
46.
47.
Slide the retainer on top the guide. Ensure that the holes of the retainer are properly aligned with the holes of the cylinder block
83115479ASD
44
83115480SDF
45
83115481X
46
83115482MKP
47
Lubricate the pistons with clean oil. Insert one piston into each aligned hole of the retainer and cylinder block. Ensure that the guide is still properly positioned on top of the three pins.
If a new swash plate or pin is being used, go to the underside of the swash plate. Insert the pin into the top, center slot. Press down on the pin until the distance between the top of the pin and the swash plate is 8.4 - 8.9 mm ( 0.33 - 0.35 in).
Slide the guide (1) onto the pin located on the side of the swash plate.
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48.
49.
50.
51.
Install the swash plate. The pin must engage the slot in the body of the control valve. The retainer must engage the groove in the piston.
83111576CV
48
83115483FN
49
83115484I
50
83111574WER
51
Place a new gasket on the outside rim.
Carefully place the cover and the shaft assembly onto the gasket. Rotate the shaft to align the support with the cylinder block.
Secure the cover with special bolts. Use the bolts to evenly draw the cover to the housing. Tighten the 3/8 in special bolt to a torque of 53 - 64 Nm 39 - 47 lb ft. Tighten the 7/16 in special bolts to a torque of 81 - 100 Nm ( 60 - 74 lb ft).
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52.
53.
54.
55.
Insert the bolt stud into the housing.
83111573CFF
52
83111572HJU
53
83111571BL
54
83111570DF
55
Slide the outer gear into the charge pump cover.
Slide the inner gear into the outer gear.
Align the coupling pin with the inner gear slot. Slide the coupling into the inner gear.
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56.
Lubricate the charge pump cover with clean oil. Align the cover pin (1) with the hole found at the top of the housing. Slide the cover onto the cylinder block and into the housing.
83111569FTR
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56
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Pump Left hand pump - Disassemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Disassembly and inspection for the left pump is the same as the right pump except for the shaft and end cover. Please refer to Pump Right hand pump Disassemble (C.20.F).
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Pump Left hand pump - Visual inspection SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Visual inspection for the left pump is the same as the right pump. Please refer to Pump Right hand pump - Visual inspection (C.20.F).
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Pump Left hand pump - Measure SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
Measuring the left pump is the same as the right pump. Please refer to Pump Right hand pump Measure (C.20.F).
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Pump Left hand pump - Assemble SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1.
The assembly of the left pump is the same as the right pump except for the shaft and end cover. Repeat steps as necessary for the left pump. Please refer to Pump Right hand pump - Assemble (C.20.F).
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Pump - Remove Drive shaft seal SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation: To remove the gear pump, refer to Pump - Remove Gear pump (C.20.F) NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The removal procedure is the same. 1.
2.
3.
Locate the drive shaft seal (1).
20115485
1
20115783
2
20115784
3
Remove snap ring (1).
Screw in self tapping screw(s) (1) into the holes (2) fitted with rubber. Pull out shaft seal with pliers.
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Next operation: Pump - Install Drive shaft seal (C.20.F)
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Pump - Install Drive shaft seal SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Currently the Bosch Rexroth electro-hydraulic pump is limited to certain serviceable parts. NOTICE: The pictures below may vary from the pump you are working on. The install procedure is the same. 1.
2.
Lubricate the lip of the seal (1) with clean oil.
20115827
1
83115476
2
20115783
3
Carefully press the new seal, with the lip down, into the cover.
NOTE: Be careful not to press the seal to far in.
3.
Insert the snap ring (1).
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Charge pump - Install SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is the same. 1.
2.
3.
Install the wear plate (1).
83115517
1
20115828
2
83115515
3
Check that the locating pin (1) and channels (2) are correct (direction of rotation Clockwise looking on the drive shaft).
Install the coupler (1).
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