Parts Manual

Skid Steer Loader L-1200

Issued February, 1982

PRIME-MOVER
 PARTS INDEX l
.'
Name Fig.#
Page~~' V' .. , _ . - ~
-----_.
( Overhead Guard Assembly
Chrysler Engine Assembly
1
2
1
2
Air Filter Assembly 3 4
.A.ir Filter 4 5
Hydrostatic Control Assembly 5 6
Hydrostatic Pump Assembly (Sundstrand) 6 8
'Hiring Assembly Schematic 7 10
P::>wer Component Wiring 8 11
Control Component Wiring 9 12
Chtysie( Engine \Viring 10 13
Hydraulic Schematic 11 14
Hydraulic Schematic Symbols 12 15
Lift Arm .A.ssembly 13 16
Lft Cylincer Assembly 14 18
Tilt Cyiir.d9; Assembly 15 19
Power Component Hydraulic 16 20
Hydraulic Motor Assembly 17 21
Hydraulic Pump and Valve Assembly 18 22
Valve Assembly (Cessna) 19 23
Pump Assembly (Rexroth) 20 24
Snap-Tach Assembly 21 25
'Nheel .A.ss3mbly 22 26
A.x!e Assembiy 23 27
Frame Assembly 24 28
Bucket and Pallet Fork Assembly 25 29
Grapple Fork Assembly . 26 30
Grapple Fork Cylinder Assembly 27 31
Auger Assembly 28 32

NOTE: For warranty see Operator's Manual.

(

(-
 FIGURE 1 OVERHEAD GUARD ASSEMBLY

. .... .~

2 cr 27

25
I
31

35
34

F1g~ Item # I Fl~. Item #

# # Part # Name Assy. # # Part # Name Assy.
1 1 03594018 Gasket, Top 2 1 22 04199015 Gauge, Oil Pressure 1
1 2 02719013 Screen, Top 2 1 23 03422029 Panel Assembly L.H. 1
1 3 03594026 Gasket, Bottom 2 1 24 03170016 Cable, Choke 1
1 4 02718015 Screen, Bottom 2 1 25 02427012 Guard, Overhead . 1
1 5 02240018 Seat Assembly 1 1 26 03581015 Lamp, Head '. ,C'" 2
1 6 92715013 Nut 2 1 27 03566017 Lamp, Rear - 2
1 7 91801516 Screw, Cap 2 1 28 01948017 Pin Cotter -.:.:. ..... '. 2
1 8 01148023 Bett, Seat 1 1 . 29 02791011 Pin, Overhead ..... . ..... . 1
1 9 02563014 Pan, Seat 1 1 . 30 02195015 Mount, Rubber '. 4
1 10 91203762 Nut 4 1 31 03592012 Washer 4
1 11 91801300 Screw, Cap 4 1 32 02026054 Strip, Foam 2
1 12 02673011 Meter, Hour 1 1 33 03086031 Seal, Roar Pan ~'. 1
1 13 03401015 Meter, Vott 1 1 34 03086023 Seal, Aoor Pan ..' 2
1 14 04200010 Gauge, Water Temp. 1 1 35 04192019 Pan, Roar 1
1 15 03359016 Clamp 1 1 36 P-11894-15 Screw, Cap 2
1
1 .
16 02179019
02179027
Switch, Ignition
Key
1
2
1
1
37 P-11261-10 Nut
38 02698027 Spacer
2
4
1 17 03422011 Panel Assembly 1 1 39 P-11045-1 Screw, Cap 2
1 18 03580017 Switch, Assembly 1 1 40 P-11170-4 Nut 4

(~- .C. 1
1
19
20
03169019
02672013
Cable. Throttle
Meter, Oil Temp
1-
1
1
1
41 02015015 Bott, Range
42 02243012 Screw, Throttle
4
2
1 21 02671015 Gauge, Fuel Level 1

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...
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 FIGURE 2 ENGINE ASSEMBLY (Chrysler)

Radiator Core Size Radiator Core Size

173(. x 20'12 x 1 Y. 15'12 x 20Y, x 2

Fig. Item # for # for

# # Part # Assy. Part # Assy. Name
2 1 P-1117Q..6 4 P-1117()..6 4 Nut, %
2 2 P"11016-3 4 P-11016-3 4 Washer, % ."
2 '.. ·3 04026010 1 04352019 1 Cooler, Oil :........ :
2 4 01992032 . 4 01992032 4 Bolt, Flange, %.75 -.- "
2 5 . 93000067 2 93000067 2 Nut ~ , ',--..-. I : ~\~~.: :~.
2 ",6 01990010 3 ." 01990010 4 . Nut --::" ':':!' ,
2 7 91801772 2 91801772 2 .Screw, Cap "~
2 , 8 04092011 1 Not Used Bracket, Cooler/Radiator :
2 9 04178019 1 Not Used Bracket, Cooler/Radiator
2 10 04125010 1 ·04125010 1 Cap, Radiator ' ...'; :', ..
2 11 52·5065 . As Req. ·52·5065 As Req. Hose, Radiator
2 12 04001012 1 04351011 1 Radiator
2 13 94040012 1 94040012 1 Cock, Drain
2 14 04177011 1 04356011 2 Strap

.......

..;" .. :.:>'.•: ......... _'_~- -.--

FIGURE 4 AIR FILTER (0242310)

Fig. Item # for

# # Part # Name Assy.
4 1 IP10-3007 Cup Assembly 1
4 2 IP1o-2523 Baffle 1
4 3 IPOO-2904 Clamp Assembly .1
4 ... 4 IP1o-1870 . Nut Assembly 1
4 5 IP1o-1275 Element Assembly 1
4 6 IP10.3008 Body Assemb.IY 1

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..

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. . 1"-. .~.. -..
.,
 ... . ASSEMBLY
FIGURE 5 HYDROSTATIC CONTROL . ~... :. ~ : ~ ..
.. - -....

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tn--'

--. - - . - -.

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---:- i1

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..
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. ".
.
1,' •. "
.;
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.. /- •• - .. ,,t. .•.. . '.
 Fig. Item # for # for
# # Part # Assy. Part # Assy. Name
2 15 04002044 1 04358017 1 'Hose, Radiator
2 16 8-14859-5 4 8-14859-5 4 Clamp, Hose
,(~
2 17 04002036 1 04357019 1 Hose, Radiator
2 18 8-14857-2 2 8-14857-2 2 Clamp
2 19 04201018 1 04201018 1 Hanger, MuHler
2 20 04164018 1 04164018 1 Muffler
2 21 04191011 1 04101011 1 Pipe, Extension
2 22 04005014 1 04005014 1 Shroud, Radiator
2 23 VB4241 073 1 V84142315 1 8elt, Gov. Drive-8ates #7280
2 24 V84027314 1 V84027314 1 8elt, Altr. Drive-Gates #7430
2 25 8-14359-4 4 8-14859-4 4 Clamp, Hose
2 26 VB4142315 As Req. 8-14423-15 As Req. Hose
2 27 04180014 1 04180014 1 Intake, Carburetor
2 28 04196011 1 04196011 1 Clamp, Muffler .
2 29 RN9Y 4 RN9Y 4 P!ug, Spark
2 30 04113015 1 04:i3015 1 Engine, Chrysler
2 31 A-14831-1 4 A-1 t!831-1 4 Clamp, Hose
2 32 01158014 1 ' 01158014 1 Filter, Fuel
2 33 52-5052 As Req. 52-5052 As Req. Hose, Fuel
2 34 04168010 1 04168010 1 Mount, Engine
2 35 04163010 1 04163010 1 Plate, Flex
2 36 04162012 1 04162012 1 Housing, Sell
2 37 0A167012 1 04167012 1 8racket, Eer.!rical
2 23 NA NA Cap, 8ell HOI~S';~g .
2 39 Transmission Assembly (See Fig.#6)
2 40 04011011 2 04011011 2 Mount, Transmission
2 41 04182010 1 04355013 1 Mount, Radiator
2 42 P-11045-2 4 P-11045-2 3 80lt, Flange % x.50
2 43 P-11261-14 4 P-11261-4 4 Nut %
2 44 P-11009-8 2 P-11009-8 2 Lockwasher '12
2 45 P-11009-6 2 P-11009-6 2 Lockwasher 3/a
( 2
2
46
47
P-11143-8
03585017
2
2
P-1143-8 2
2
Screw, Cap 3/a x 2
Nut 1/2 Top Lock
2 48 P-11854-3 6 P-11854-3 6 Screw, Cap 5/'6 x .75
2 49 P~11009-5 6 P-11009-5 5 Lockwasher S/, 8
2 50 P-11854-10 1 P-11854-10 1 Screw, Caps/, 6
2 51 P-11016-2 1 P-11016-2 1 Washer, Flat 0/,6
2 52 04237013 1 04237013 1 Filter, Oil Element
2 C432i014 1 Shroud, Air

*NotShown

NA Not Available

:'SP~
FIGURE 3 AIR FILTER ASSEMBLY

(
7 \

/
/
I
\
\
\

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---- ---

Fig. Item # for

# # Part # Name Assy.
3 1 8-14859-6 Clamp Hose 2
3 2 04008034 Hose, Air Cleaner 1
3 3 P-25332-1 Tie, Clamp 1
3 4 02423010 Filter, Air (See Fig. #4) 1-
3 5 P-11170-6 Nut 2·
3 6 P-11016-13 Washer, Rat 2
3 7 04236015 Mount, Air Cleaner 1

',-
. .,.

SP-4 "
:." : ....
' - "
'. "i:
, ;--:'-}1-'
 Fig. Item II for
II # Part II Name Assy.
5 1 01134014 Grip, Lever 2
5 2 01990010 Nut 4
( ~
5
5
3
4
02246016
P-11045-2
Shock
Screw, Cap
2
2
5 5 P-11170-4 Nut 3
5 6 03774016 Strip, Centering 2
5 7 P-11143-7 Screw, Cap 2
5 8 P-11847-7 Screw, Cap 2
5 9 P-11129-6 Nut 2
5 10 02638015 Handle Assembly Br:+4. L .M. 1
5 10 02638023 Handle Assembly~. ~. tt. 1
5 11 P-11160-11 Fitting, Grease 2
5 12 02642015 Arm Assembly R.H. 1
5 12 02642024 Arm Assembly L.H. 1
5 13 01992016 Bolt 4
5 1-+ 02652015 Arm Steering R.H. 1
5 14- 02652023 Arm Steering L.H. 1
5 15 02739011 Spring 2
5 16 P-11143-4 Screw, Cap 4
5 ~7 02629014 End, Rod R.H. 6
5 18 P-11246-6 Nut 10
5 19 02644012 Rod 1
5 20 P-11170-6 Nut 7
5 ,.!
'-
1
. P·1104S-10 Screw, Cap 1
5 22 02655019 Lever. Pump 1
5 23 P-11936-6 Washer 4
"-
5 24 02763010 Bushing 2
5 25 03430014 Neutral Assembly R.H. 1
5 26 03430022 Neutral Assembly L.H. 1
5 27 02452019 Plate, Control 2
5 28 P"11016-3 '!/asher, Flat 4
C \
5
5
5
29
30
31
03298016
02629022
P~11143-9
Rod
End, Rod L.H.
Srr o '\!, ~~.,
2
2
...,.,
5 32 03413010 Rod,7V2 2
5 33 P·11831-1 Nut, Lock 2
5 34 02454015 Lever, Pump Control 2
5 35 P-118S4-7 .... Screw, Cap 2
5 36 P-11170-5 Nut, Lock '6
5 37 P·l1073-1 Pin, Roll 2
5 38 04175015 Bracket. Pump 1
5 39 Pump Assembly (See Fig. 6) 1
5 40 02045012 Spring 4
5 41 03n2010 Pin 2

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 FIGURE 6 HYDROSTATIC PUMP ASSEMBLY (Sundstrand) (02081016)
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12

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41

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33-~

P
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..
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FIg. Item . IIfor

II II Part II Name Assy.
6 1 F9003530-31 00 Nut, Hex 4
6 2 F3102320 Stud 4
6 -3 F9001465-0004 Bearing, Needle 1
6 4 F3102304-02 Housing, Charge Pump .1
6 • F3102307 Gasket 1
6 5 F9004101-153O DRing 1
6 6 F3102515-0oo2 Gerotor Assembly 1
6 7 F9004875-0023 Pin 1
6 8 F3102309 Shaft. Charge Pump 1
6 9 F900131 0-001 0 Bearing. BaJl 1

~.
6 10 F90063000078 Ring, Retaining 1
6 11 F3102305 Coupling 2
6 12 F9510248 Valve, Check 4

.-
SP-8
.... .. ' ...
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 FIGURE 8 POWER COMPONENT WIRING

Secure this
part locally

"'-

/ .....-... _.

Fig. Item
# # Part # Name
# for
8
Assy.
1 Part of Chrysler Engine
8 2 NSS Battery
8 3 P-11170-6 Nut
8 4 P-11016-13 4
Washer, Rat
8 5 02036011 4
Bracket, Battery
8 6 P-15759-3 1
Cable, Battery
8 7 03397016 2
Clamp, Battery
1
( ( NSS - Not sold separately

.::
:. . SP-11
FIGURE 9 CONTROL COMPONENT WIRING

(_
Fig. !t·~jn # for
# # Part # - Name Assy.
9 1 Harness Assembly (See Fig. 10) 1
9 2 02675017 Sender, Fuel 1
9 3 02676015 Sender, Oil Temp. 1
9 4 04174017 Harness Assembly 1
9 5 Valve Assembly (See Fig. 19) 1
9 6 P·25332·1 Tie, Clamp 1
9 7 20 Amp Fuse (secure this part locally) 1
9 8 02179027 Key 2
9 9 02179019 Switch, Ignition 1.
9 10 02673011 Meter, Hour .1
9 11 03401015 Meter, Volt 1
9 12 04200010 Gauge, Water Temp. 1
9 13 04174025 Harness Assembly"-r 1
9 14 04199015 Gauge, Oil Pressure '.. 1
,9 15 02671015 Gauge, Fuel Level
~
.1
9 16 02672013 . Meter, Oil Temp.
o :

.1

SP-12 1 .
FIGURE 10 CHRYSLER ENGINE WIRING

Ag. Item 1# for

# # Part # Name Assy.
10 1 04173019 Solenoid, Anti-Diesel 1
10 2 04194015 Sender, Water Temp. 1
10 3 04195013 Sender, Oil Pressure 1
10 4 04174033 Harness, Wiring 1
10 5 Engine (See Fig. 2) 1
FIGURE 11 HYDRAULIC SCHEMATIC

----------.
I
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I I
I I
I I
I I
I
I ( i

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 FIGURE 12 HYDRAULIC SCHEMATIC SYMBOLS

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Hyd"'ullc
<!> Coole(
Una Croc.sI~

-<I>- FiIt.r -rl-H~~Wk

lInM Joining

-<r CheQV.,..,. W
~ Femal4 Coup4er

--7---t J.4. Coupler

Cylind«

1- ---1 CompoMC'lt
L ___ J ~te

Q Pump

0 EngiM
Erdoeute

..

~ Control Lewt
..
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 5 4

iel
6

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 FIg. Item ' ... . . ..........
.... .' .
0r:' .. :: .11 for ..
....: , # # Part # Name Assy.
13 1 02109016 Boom Assembly 1
13 2 P·11143-8 Screw, Cap 2
~

13 3 P·1117D-6 Nut 2 ( \

C 13
13
4
5
03036036
02451011
Pin
Bushing
8
8
j
.l

13 6 03506013 Clamp 2
13 7 02772011 Hose Assembly 3
13 8 02866012 Hose Assembly 1
13 9 94011039 Tee 2
13 10 02771013 Hose Assembly 4
13 11 01161017 Clamp 2
13 12 02411015 Pedal, Center 1
13 13 01864033 Cylinder Assembly (See Fig.#14) 2
13 14 03036010 Pin 2
13 15 03036028 Pin 2
13 16 02409010 Pedal, R.H. 1
13 17 02171015 Cylinder Assembly, L.H. (See Fig. #15) 1
13 18 02171023 Cylinder Assembly, R.H. (See Fig. #15) 1
13 19 94015049 Tee 2
13 20 02770015 Hose Assembly 4
13 21 P·11016-12 Washer, Flat 6
13 22 02521012 Plate, Cover 1
13 23 P·11246-5 Nut 2
13 2~ 2·11016-11 Washer, Flat 2
13 25 01813014 Bolt, Carriage 2
13 25 02377019 Valve (See Fig. #19) 1
13 27 02034015 Plate, Valve 1
13 28 ~
94001163 Adapter 6
13 29 02773019 Hoss Assembly 2
13 30 01817024 Cap, Plug 1

(
\.
13
13
13
31

33
32
01799024
01800029
01818022
Coupler, Female
Coupler, Male
Cup, Plug
'1
1
1
,C
13 34 940070"!fL_ Elbo~~:J_o 2
13 -"'r--~bo ~--"-&tl(fFead
2
13 "': _35 02703016 Ptate-,"Cover" ~ 1
13 ~~6 02436013 Rod, Pedal 3
13 ~7 01115014 .yoke'········ .'
3
13 :38 01948019 Pin, Cotter 2
13 39 01847021 Rod 1
13 40 01804013 Pin 3
13 41 <', 01809013 Pin, Cotter 3
13 ~2 P·11160-11 Fitting, Grease 3
13 . 43 02410017 Pedal, L.H . 1..
..
...
'

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 FIGURE 14 LIFT CYLINDER ASSEMBLY (01864033)
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.

12
'.

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.
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10~'),
14 13.~~(f\\~
15~~~~
2~
c "0 'I'

Fig. Item # for

# # Part # Name Assy.
14 1 P-11160-13 Fitting, Grease 2
14 2 02169010 Retainer 1
14 3 A-14908-12 Nut,lock . 1 :'
14 4 02939017 Tube, Cylinder 1
14 5K NSS Ring, Wear .- -.' .'1
14 6 02114015 Piston 1
14 7 02915017 Seal, Piston 1
14 8 P-11015-24 o Ring 1
14 9 P-11015-1 o Ring '.' .
1
14 10 02899013 Spacer 1
14 11K NSS .0 Ring 1
14 12K NSS Ring, Sack-up 1
14 13 02115013 Head, Cylinder 1
14 14K NSS Seal, Rod 1
14 15K NSS Seal. Wiper 1
14 16 02116029 Rod. Cylinder 1
14 K 02622018 Kit, Seal (Contains parts indicated by letter"K") 1
(-
NSS - Not Sold Separately

,'. ' ...' ..!:•....~ ~ -~ ....~ .

:.,,,.
. ... SP-18 .; "'.
 FIGURE 15 TILT CYLINDER ASSEMBLY (02171015,0,2171023)

,~----'"
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10
.

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12~~~
11 \

13 .

1~

Fig. Item # for

# # Part # Name Assy.
15 1 02169010 Retainer 1
15 2 A-149Q8..12 Nut, Lock 1
15 3K NSS Ring, Wear 1
15 4 02114015 Piston 1
15 5 02915017 Seal, Piston 1
15 6K NSS o Ring 1
15 7K NSS o Ring 1
15 8K NSS o Ring 1
15 9K NSS Ring, Backup 1
15 10 02115013 Head, Cylinder 1
15 11K NSS Seal, Rod 1
15 12K NSS Seal, Wiper 1
15 13 02116037 Rod, Cylinder 1
15 14 P-11160-13 Fitting, Grease 1
15 15 P-11160-14 Fitting, Grease 1
15 16 02149062 Tube, Cylinder R.H. 1
15 16 02149054 Tube, Cytinder LH. 1
( ..... 15 K 02622018 Kit, Seal 1

NSS - Not Sold Separately

:-
.' ".
-.;-
SP-19
FIGURE. 16 POWE.R COMPONE.NT HYDRAULIC (

«'

#t tor .
AsS'I·
1 :-
4-·
ttern Name 4
Flg. part #t iransmission AsSembly {see Fig./l6)
# 2
#t Fitting 2
1 94Q01329
16 2 Fitting 2
16 94Q01189 plate .1
3 '.
16 0328101 1 Spacer
Motor Assembly{see fig. /117)
-
3-
4
16
5 0348 1017
16 03062015 Hose AsSemb\y
6
16
7 027160 13 Hose AsSemb\Y
16 0271502.3
8
16

•
 FIGURE 17

17

24
(
&.ftre~
/CjS/ - 1'4
Affer /~
ItJg') - . ~ 21

Fig. Item II for

II /I Part II Name Assy.
17 1K NSS Seal 1
17 2K NSS Ring, Retaining 1
17 3K NSS Spacer 1
17 4K NSS Washer 1
17 5K NSS Seal, Shaft .~
1
17 6 RMAB012002 Housing ~{ 1
2
7K Seal, Ring
.;~~ V~ ~t.-"
17 NSS
17 8~ -N-&e f<Y C (. ( (, .3 Washer, Thrust .
Bearing, Thrust.!}... C { ~ Lf
7 ~v
2
1
17
17
.-9
_10
11
R067029
R070502
02421014
Bearing :;. c: 11"~ 9
Nut
.~ -\ \.'>~\r 1

~~L~ ~'
17
17 ~2 . R039027 Key c;t.o.'''' '(
I _ J !Y
17
17
17
...... 13
14
151-
R091442
R070501
R067031
Shaft, Coupling
Bearing ;(I) I 7
Bearing. Thrust
.;t
r?r01 / 9.,(
v " '"'

17 16 RMA=24300u - Link. Drive

17 17 R477259 Plate, Wear ,
17 -18 RMAE247000 Set, Rotor.). CiS /D _
{ 17 ... 19,. RMAB018000 Commutator Assembly I S{ ~
,J...c:
1- 20 NSS Commutator. Ring
(~
.(

H 21 R099066 Sleeve
17 22 RMAE016000 Cover, End
17 23 R021273 Bolt
17 24 RMAE015000 Manifold
17
17
25
..- 26r-
R4n260
RMAB500003
Plate. Manifold
Kit. Seal (Contains parts indicated by letter )K'G G<;;CrU \.
NSS· Not Sold Se::-aratSly ''I.P$b'~~OI L. 1l '\l SP·21
c
 FIGURE 17 HYDRAULIC MOTOR 'ASSEMBLYMAE24029 (03'062015)
?h'\~·16.~oO
( r;

14

17

fig. Item 'for

, , Part' HarM Aaay.
17 1K NSS Se~ 1
17 2K NSS Rmg.R.m~~g 1
17 3K NSS Spacer .1 :-
17 «NSS Washer 1•
17 5K NSS Seal, Shaft ... ' .1· .
17 6 RMAB012002 Housing . 1
17 7K NSS Seal, Ring 2
17 8K NSS Washer, Thrust 2
17 9 R067029 Bearing. Thrust 1
17 10 R070502 Bearing 1
17 11 02421014 Nut 1
17 12 R039027 .,.. Key 1
17 13 -flOi~~- Shaft. CoupBng 1
17 14 R070501 Bearing 1
17 15 R067031 Bearing, Thrust 1
17 16 RMAE243000 Unk. Drive 1
17 17 R4n259 Plate, Wear 1
17 18 RMAE247000 Set. Rotor 1
17 19 RMAB018000 Commutator Assembly 1
17 20 HSS Commutator, Ring 1
17 21 R099068 Sleeve 1
( 17
17
17
22
23
24
RMAE01800Q
A021273
RMAe015000
CoYer. End
Bolt
Manifold
1
7
1
17 25 R477260 Plate. Manifold 1
17 26 (~500003") lOt. Seal (Contai1s parts lndicated by leUer "K"1
NSS • Not Sold Sepandely 11~ b4- gDo I ~ ..... .', ..••.
. SP·.;,.·
';~
( ,

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 FIGURE 17 HYDRAULIC MOTOR ASSEMBLY MAE24029 (03062015)

21

7
;'

Ag. item
Part , Name
*for
II
17
*
1K NSS Seal
Aay.
1
17 2K NSS Ring, Retaining 1
17 3K NSS Spacer 1 -
17 4K NSS Washer 1 -
17 5K NSS Seal, Shaft . -:. - 1 ..
17 6 RMABOl2002 Housing 1
17 7K NSS Seal, Ring 2
17 8K NSS Washer, Thrust 2
17 9 R067029 Bearing, Thrust 1
17 10 R070502 Bearing 1
17 11 02421014 Nut 1
17 12 R039027 Key 1
17 13 _~~_~~2; Shaft, Coupnng 1
17 14 R070501 Bearing 1
17 15 R067031 Bearing, Thrust 1
17 16 RMAE243000 Unk, Drive 1
17 17 R4n259 Plate, Wear 1
17 18 RMAE247000 Set, Rotor 1
17 19 RMA8018000 Commutator Assembly 1
17 20 NSS Commutator, Ring 1
l 17
17
21
22
A099066
RMAEOl6000
Sklew
Cover, End
1
1
17 23 R021273 Bolt 7
17 24 RMAE015000 Manifold 1
17 25 R477260 Plate, Manifold 1
17 26 RMAB5OOOO3 Klt, Seal (Contakls parts Indicated by letter uK'j
NSS • Not Sold Separately ...;: .'. ··'.,~; . SP-.;.·

--. ,._--- -._---- -". - ., .... '-. ~ .. ~." ... ~'- ... ~ ~""~
"- FIGURE 18 HYDRAUUC
< " ..
PUMP AND VALVE ASSEMBLY ..
..
'
'..-: "

2
 Fig. Item II for
II # Part # Name Assy.
6 13 F3102142 Plug 4
"
,'" 6 14 F900420 1-31 00 o Ring 4
( -.-r 6
6
15
16
F3101061
F9001214-4400
Spring
Bull
4
4
6 17 F90051 00-4400 Plug 4
6 F900420 1-2500 o Ring (part of #17) 4
6 18 F9005001-1200 Plug 4
6 19 F9510303 Relief, Charge 1
6 20 F3102818 Plug 1
6 21 F9004201-5000 o Ring 1
6 22 F9510362 Shim 2
6 23 F3102280 Spring 1
6 24 F3102274 Valve, Relief 1
6 25 F90021 02-5075 Connector 2
6 2S F9900096 lube Assembly 1
6 27 F3102399 End, Cap Pump 1
6 2e F9510~ Bear~ 2
6 29 ~31021 ,...Ia[e~ alve 2
6 30 F3102789 Cylinder 2
6 31 F3102308 Shaft, P'Jmp 1
6 22 F3102400 Gasket 2
0 ~ F31u2058 Plate, T:arust 2
6 0.t F900469Q-3112 P:n, Roll 8
6 :!:: F3102272 Swashr;late 2
6 "..... ::>.... F9510295 BearjoQ 2
6 37 F9007300-5 024 Screw, Cap 2
6 38 F9009651-5000 LockN:lsher 2
6 39 F9007300-4430 Screw 8
6 4D F90051 00-9000 Plug ,2
6 F900420 1-7500 o Ring (part of #40) 2
( \.
6
6
41
42
F9008000-0081
F900 1465-0007
Seal, Lip
Bearing, Needle
4
4
6 43 F3102647 Shaft turn 4
r-
Q ~> .. ,.Ir F310231E '. t ···11 ...... ~ ~-
.. t·................. ,.,::.; j
6 45 F3102314 Gasket 1
6 46 F9006200-0069 Ring, Retaining 1
6 47 F3102415 End, Cup Pump 1
6 48 F900480Q-1908 Pin 2
6 49 F3102693 Shaft, Pump 1
6 50 F9008000-0049 Seal, Lip 1
6 51 F3102536 Housing 1

. ,

( l

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 "en i1
l'
..4 '"
(i)
o C
:D
m
......
_ _ _ __
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______ _ _ _ _ _ _ _ _ _ -1I

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___________ ~
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.... ....
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(

A
B! 4

I~XI XIJ;II'!~
B

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C FIg.
#
Item
# Part # Name
# for
Assy.
19 1 VA-10628 Wiper. Rod 3
19 2 VA-10815-114 o Ring 6
19 3 NA Body. Valve 1
19 4 VA-1325-117 Poppet 3
19 5 VA-1325-84 Spring 3
10 ~ VA-10816-906 o Ring 3
19 7 VA-1325-40 Plug 3
19 8 VA-10782-1900 Valve. Relief 1
19 9 VA-1225-55 Cap, End 1
19 10 VA-10458 <. Screw 1
19 11 VA-1225-4 Spacer 1 _
19 12 VA-1225-18 Spring, Return 1:
19 13 VA-1225-6 Washer 1
19 14 NA SPool. Valve " 1
19 15 VA-30028-8208P Screw with Lockwasher 6
19 16 VA-1335-7 Plug, Detent 4
19 17 VA-10065 Ball, Steel 4
19 18 VA-1260-25 Spring. Detent 4
19 19 VA-1225-155 Cap, End 2
19 20 VA-1604-5 Spool. Detent for Spool #25 1
19 VA-1335-5 Spool, Detent for Spool #24 1
19 21 VA-1335-4 Spacer 2
19 22 VA-1335-8 Spring, Detent 2
19 23 VA-1335-3 Washer, Return 2
19 24 NA Spool. Valve 1
19 25 NA Spool, Valve 1

l 19
19
K
K
VA-1225-40
VA-1604-8
Kit, Spring Ctr. (Parts 9, 10, 11, 12 and 13)
Kit. Spring. Ctr.
(Parts 15. 16.17.18.19.20.21.22 and 23)
1

1
19 K VA-1335-17 Kit. Detent 1
.'-
. '.
NA .. Not Available SP-2:
' t ..,~
~~,..~ ~ .. ,." < __ ..- - ... _L_ ~~ - .. ~.-~~-
FIGURE 20 REXROTH IMPLEME~ PUMP S15S-9-D-H-1-2-R (02002014)

(
3

00 not force
nylatron sea I
below surface

Bronze face
toward gears
9
10

13

t
Fig. Item # for
# # Part # Name Assy.
20 1 VF60101-038 Screw, Cap 4
20 2 VF61201-003 Washer 4
20 3 VF1501-542-002 Cover, Rear part 1
20 4 VF761 05-003 Plug, Pipe 1
20 5K NSS Seal, Gasket' '1
20 6 VF1501-047-001 . Plate, Thrust 1~
20 7 VF1501-032-008 Gear, Driven ···1
20 8 VF1501-031-004 Gear, Drive 1
20 9 VF1501-048-001 Plate, Wear 1
20 10K NSS Spacer 1
20
20
20
11K
12
13
NSS
VF6901-OO1
VF1501-553-005
Nylatron
Pin, Dowel
Body
.,..
-
.
1
'.2
1
20 14 VF1501-076-001 Seal, Shaft 1
20 K VF1501-635-007 Kit, Seal 1

NSS - Not Sold Separately

( ~

SP-24 - .
- .
,-.r·
, ,>.~~~~~:' " ~'., -;..~~.~~~:.. ~ ........ ~:' ,,::,,:~ ~:
 FIGURE 21 SNAP.TACH ASsEMSlY
(~

Ag. Item
# # Part #
21 1 Name ... ...
-
.:,,;..
21 01809012 -
2 02816017 Pin, Cotter
21 # for
02816025 Pin, l.H. .-.
t',

. Assy.
21
21
3
4
P-11160-11 Pin, A.H. -.. 2·
02829010 rltting, Grease 1-
Plate, QUick attach 1
2
1

SP-2£
FIGURE 22 WHEEL ASSEMBLY

( "\

)
4
3

Fig. Item # for

# # Part # Name Assy.
22 1 A·30201 Valve, Stem 1
22 2 02111011 15 x 6 Rim Wheel 1
22 3 02110013 16 x 8.25 Rim Wheel 1
22 3 02087014 Tire 7.00-15 1
22 02357011 Tube Inner 1
22 4 A·30192 Tire 10.00 x16.5 1
22 03080017 7.00 x 15 Wheel Assembly Set of 4
22 03112018 10 x 16.5 Wheel Assembly Set of 4

:~:: ~-. -r- ...

..•. :....
"
" .,

.-'

SP-26 !.'
.:;.! :
 ,;.'. ,

FlGURE 23 AXlE ASSEMBLY

@
I

NOTE: Nut (item #15) should be torqued to 300 ft. Ibs.

C NOTE: The snap on connecting link must NOT face one another (See Fig. #13 of Operator's Manual).

Fig. Item # for

# # Part # Name Assy.
23 1 02626010 Nut 24
23 2 02435015 Axle Assembly 4
..,'"'
t::..) 3 02C93011 SBal 4
23 4 02094019 Cone 8
23 5 02094027 Bearing 8
23 6 02166032 Housing 2
23 7 02311017 Gasket 8
23 8 02309020 Gasket 8·
23 9 02088020 Sprocket, Wheel ":4
23 10 P-11016-10 ~asher, Flat 4
'~- . 23 11 02470011 Nut .04
23 12 91034159 Pin, Cotter 4
23 13 02529024 Chain , 2
23 ·14 02441046 Housing ·0 2
23 15 02421014 Nut 1
23 16 02083020 Sprocket 1
023 17 03410016 Key 1
23 18 03585017 Nut 40
23 19 02075019 Screw, Square Head 8
23 20 03062015 Motor (See Fig. #17) 2
23 21 02528026 Chain 2
23 22 02869016 Washer 32
?
(,-

,0
SP-27
 AGURE 24 FRAME ASSEMBLY
7

3 __

t
18"'1 t-1---10

14 13
8

L---
~ /'2
,r~11

16

FIg; Item
# for
# # Part # Name Assy.
24 1 01171016 Cap, Fuel 1.
24 2 P-11129-6 Nut 2
24 3 02471019 Valve, Fuel Tank 1
24 4 02335017 Tank, Fuel 1
24 5 02661016 Shield, Filler 1
24 6 02266014 Pin, Grill 2
24 7 04104014 Grill Assembly 1
24 8 01809013 Pin, Cotter 4
24 9 03418010 Lock, Boom 1
24 10 02200046 Frame, Main 1
24 11 P-11170-6 Nut 16
24 12 P-11016-13 Washer, Rat 16
24 13 02260016 Cover, Side 2
24 14 02310019 Gasket, Cover 4
24 15 02309020 Gasket, Cover 4
24 16 P-11816-4 Plug 8
24 17 03203015 Cover, Assembly 1
24 18 03431012 Dip Stick 1

~-
24 19 P-11854-5 Bolt 2
24 20 03201019 Lever Assembly 1
24 21 P-11129-10 Nut 2
24 22 03531010 Clamp 2
24 23 03519016 Support 2
SP-28
 RGURE 25 BUCKET AND PALLET FORK ASSEMBLY .
" ... .
....
..
'!t .
.. ,

( 2

-.
3--~,
5~ 4

F1g. Item # for

# # Part # Name Assy.
25 1 02125012 Bucket, Dirt 55" 1
25 1 02151017 Edge, Cutting 55" 1
25 1 02125020 Bucket, Dirt 62" 1
25 1 02151025 Edge, Cutting 62" 1 =-
25 2 03192010 Bucket, Light Materials 62" 1 -
25 2 03196020 Edge, Cutting 62" 1
25 2 . 03192028 Bucket, Ught Material 84" 1
25 2 03196020 Edge, Cutting 84" . 1
25 3 P-11261-6 Nut 8 or 9
25 4 P-11143-8 Screw, Cap S·or 9
25 5 03188019 Fork Manure 8 or 9
25 6 03197010 Bucket, Fork 55" 1
25 6 03196038 Edge, Cutting 55" 1
·25 7 03692010 Fork, Manure 55" 1
25 7 03196038 Edge, Cutting 55" 1
25 7 03212016 Bucket with teeth, Dirt 55" 1
25 7 02151017 Edge, Cutting 55" 1
25 7 03668011 Fork, Manure 62" 1
I 25 7 03196012 Edge, Cutting 62" 1
( \- 25
25
7
7
03213014
02151025
Bucket with teeth, Dirt 62"
Edge, Cutting 62"
1
1
25 8 02824010 Fork, Pallet 1
..... '

~., SP-~
" AGUR"E 26 GRAPPLE FORK ASSEMBLY (03669019) .
'-.,
-....' .° 0 .. :",

(;

. Fig. Item # for

# # Part # Name Assy.
26 1 01817024 Plug 1
26 2 01799024 Coupler, Female 1
26 3 94014033 Tee 1
26 4 01800029 Coupler, Male -·'1
26 5 01818022 Cap l'
26 6 02511021 Hose Assembly . -- 2
26 7 02506022 Hose Assembly ~ ... . ·2
26 8 03404019 Mount, Grapple 1
26 9 02503036 Pin 8
26 P-11045-6 Screw, Cap 8
26 P-11170-4 Nut 8
26 10 94013019 Tee 1
26 11 01865015 Cylinder Assembly (See Fig. #27) 2
26 12 03403011 Arm, Grapple 1
26 13 03212016 Bucket, Dirt 55" 1
26 13 02151017 Edge, Cutting 55" 1
26 13 03692010 Bucket, Manure 55" 1
26 13 03196038 Edge, Cutting 55" 1
26 13 03213014 Bucket. Dirt 62" 1
26 ' 13 02151025 Edge, Cutting 62" 1 (
26 13 03668011 Bucket, Manure 62" 1
26 13 03196012 Edge, Cutting 62" 1
*Not shown
SP-30
 - .

FIGURE'lJ GRAPPLE FORK CYLINDER ftSSEMBLY'(01865015)

',,'

Fig. Item # for

# # Part # Name Assy.
27 1 P-11160-11 Fitting, Grease - 1
27 2 P-11160-13 Fitting, Grease ........... 1
27 3 02169010 Retainer -- 1 :-
27 4 A-14908-12 Nut, Lock 1
27 5 02150019 Tube, Cylinder 1
27 6K NSS Ring, Wear 1
27 7 02114015 Piston 1
27 8K NSS Seal, Piston 1
27 9K NSS o Ring 1
27 10K NSS o Ring 1
27 11 K NSS o Ring 1
27 12K 02918011 Ring, Back-up 1
27 13 02115013 Head, Cylinder 1
27 14K NSS Seal, Rod 1
27 15K NSS Seal, Wiper 1
27 16 02116061 Rod, Cylinder 1
27 K 02622018 Kit, Seal (Contains parts indicated by letter 11K")
( (
NSS - Not Sold Separately

SP-31

___ ______ ___ __ ' _ ..... ,

~
~
~
~
~
~
h
~
-
_
_
_
 . FlGURE 28 AUGER AlTACHMENT ASSEMBLY .. . . ,
• ~ • '.: • I _.

(
A
WARNING

25
(

26

27

. SP-32
 -~-:{;:";t\"'::~-·i?~~~;~~*-~~t~<.~:;~g{',!rr ,--." . ·'i;"':;'~~~~~_~~~~I._~~~~'~}:f~~!f~'·'

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Fig. Item I for
# # Part # Name , ," Assy.
28 1' 02884014 Decal, Auger 1
28 2 03191012 Frame, Attachment 1
( , 28
28
3
4
P-11170-6
P-11009-6
Nut
Lockwasher
4
4
28 5 P-11016-3 Washer, Flat 4
28 6 03122017 Plate Assembly 1
28 7 02956011 Trunnion Assembly 1
r" 28 8 01948019 Pin, Cotter 4
28 9 02998013 Pin 1
28 10 P-11170-8 Nut 5
28 11 P-11009-8 Lockwasher 4
28 12 03062015 Motor, Hydraulic 1
28 13 A-14994-11 Screw, Cap 4
28 14 02998021 Pin 1
28 15 03249019 Bracket, Motor 1
28 16 P-11271-7 Screw, Set 1
28 17 02959015 Adapter 1
28 18 03507011 Nut, Retainer 1
28 19 P-14994-17 Screw, Cap 1
28 20 P-11016-4 Washer, Flat 1
28 21 01817024 Plug 1
28 22 01800029 Coupler 1
28 23 01817024 Cap 1
28 24 01799024 Coupler 1
28 25 03522027 Hose Assembly 2
28 26 94010114 Elbow 2
28 27 01764019 Auger 9" 1 ~, ..
28 27 01765017 Auger 12" 1
28 27 01766015 Auger 15" 1
28 27 01767013 Auger 18" 1
28 27 01768011 Auger 9" ,1
C
)

\..- 28 27 01769019 Auger 12" 1

28 28 01768011 Cutting Edge 9" (Includes bolts and nuts) 1
28 28 ,01769019 Cutting Edge 12" (Includes bolts and nuts) 1
28 28 01770016 Cutting Edge 15" (Includes bolts and nuts) 1
(" 28 28 01771014 Cutting Edge 18" (Includes bolts and nuts) 1
28 29 03771012 Point, Auger 1

( l

SP-33
 ., .
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 Operator's Manual
(
Skid Steer Loader L-1200

(
®
Issued May, 1981
PRIME-MOVER
SKID STEER LOADERS
PRIME-MOVER
(-
WARRANTY
The Prime-Mover Co. warrants that all Prime-Mover Skid Steer Loaders are free from defects in material
workmanship. This warranty extends exclusively to Distriubtor and to the original purchaser froin
Distributor or The Prime-Mover Co.
The Prime-Mover Co. will, at its expense, replace or repair, f.o.b. Muscatine, Iowa, any equipment or parts
manufactured by it which prove defective in material or workmanship provided purchaser gives notice of such
alleged defect within the warranty period, and, if requested by The Prime-Mover Co., returns such equipment
or parts to The Prime-Mover Co., Muscatine, Iowa, transportation prepaid.
The warranty period is:
Twelve months, or 500 hours, whichever comes first, after date of purchase.
The Prime-Mover Co. may elect to make such replacement or repair at an establishment authorized by it.
The Prime-Mover Co. undertakes no responsibility for work done or expense incurred for replacement or
repair not specifically authorized by its home office at Muscatine, Iowa.
This warranty does not apply:
• To engines, attachments, accessories, batteries, and tires. These items are warranted separately by
their respective manufacturers.
• To equipment or parts subjected to overload, misuse, neglect, alteration or accident.
• To normal maintenance service items, such as oils, lubricants, filters, fuel injection systems,
ignition system, clutches, alternator, fan belts, pivot pins.
• To normal replacement of service items such as seals, gaskets, hoses, tube-lines, rubber lines,
wiring, electrical connections, etc., due to wear, application, and environment.
• Loose bolts, nuts, or fittings, due to overtightening or vibration, after 30 operating hours.
• Problems in fuel or hydraulic system caused by contamination such as water or dust.
o Cooling system problems caused by air flow obstruction.
• Hauling expense
The Prime-Mover Co. reserves the right to make certain changes in design and changes or
improvements in its products at any time without any obligation to make such changes or improvements
in its products previously manufactured.
Performance under this warranty shall be the sole remedy of the Distributor or theoriginal purchaser and
The Prime-Mover Co. shall in no instance be liable for special, general, incidental, or
conseqOentialdamages.
This warranty is expressly in lieu of all other warranties express or implied, including any warranty of
merchantability or fitness for a praticular purpose.

THE PRIME-CO.
MUSCATINE, IOWA 52761
DIVISION, HON INDUSTRIES
 INTRODUCTION
The operator should read this manual thoroughly
so that the important facts about this unit and the
( contents of the manual are known. The safety of
the operator and the reliability and performance of
this unit will be determined by the knowledge of
the contents of this manual.
Each section of this manual is clearly identified
and is divided into smaller sections. The Table of
Contents can be used to find the information that
is needed.
The model number and serial number for this unit
are stamped on a plate located onthe left upright
below the Cross Frame Support.
"Right" and "Left" are determined from a position
sitting on the seat and looking forward.
WARNING: Some drawings may show door(s),
guard(s), or shield(s) opened/removed. BE SURE
that all door(s), guard(s), orshield(s) are in their
proper position, BEFORE machine is operated.
To New Prime-Mover Owners:
Our Company would like to take this opportunity
to thank you for joining (or rejoining) the
increasingly large community of companies and
individuals finding profit in the use of Prime-Mover
equ ipment.
The Prime-Mover Skid-Steer Loader which you
have just purchased was carefully designed and
manufactured to ensure minimum cost, maximum
c reliability, and easy service. Extensive testing and
high standards of quality control assure that these
standards are maintained.
To keep your Prime-Mover loader in good
condition the periodic maintenance and lubrication
should be followed.
Prime-Mover tru cks are also backed by a network
of dealers who were chosen for their experience
and reliability. They will assist you in keeping your
Prime-Mover loader in peak operating condition.
If you will take a moment to record the information
it will be of help to you when parts and service
assistance is needed.
The Serial No. of my L-1200 is _ _ _ _- - - -
It was delivered to me on _ _ _ _ _ _ _ _ __
I purchased my machine from
I can contact my Prime-Mover distributor by dialing
PRELIMINARY SERVICE
Examine ypur Prime-Mover skid-steer loader care-
fully to determine. whether or not it has been
damaged in shipment. Any damage should be
immediately reported to the transportation company.
The new machine should be checked out by a
qualified mechanic. An arrival and pre-delivery
checklist is sent with each machine. The sheet is to
be returned to The Prime-Mover Co. to validate
warranty and to assure that the user has received a
quality Prime-Mover product ready to do its job.
All operators should be trained before operating this
or any loader. This training should include a study
of acceptable operating practices and actual super-
vised driving experience. The operator should be
familar with all operating instructions before
attempting to operate the machine.
Check the engine oil level and hydraulic oil level
before operation. Check to determine that the
battery is adequately charged, properly installed
and connected.
OPERATION
There are certain hazards that cannot be avoided
solely by mechanical means in the everyday use of
skid-steer loaders. Only the intelligence, good sense
and care of the operator, along with proper
maintenance will assure that the loaders are
operated properly. It is important to have trained,
reliable personnel operating your loaders. If at any
time the operator finds that the loader is not
performing properly, he should discontinue opertion
of the loader and report the condition to his
supervisor for correction.
Move and transport materials that have been
properly and evenly loaded in 25 Iowa position as
possible. Travel in a direction of maximum visibility.
TABLE OF CONTENTS
Introduction 1
Operating Rules 2
Warnings 4
Controls and Safety Equipment 5
Operation 10
Lubrication 14
Service Schedule 14
Service 17
Troubleshooting Guide 27
Specifications 31
SO-1

O'P'ERATING RULES
OPERATOR CARE OF THE LOADER
B. Prepare the machine for starting:
Before operating the Loader, check its condition,
giving special attention to the:
1, Tires
2. Instruments
3, Lights
4. Controls
5. Lift and bucket systems
6, Brakes
7. Steering mechanism
8. Daily lubrication (see service chart)
If the unit is found to be in need of repair or in any
way unsafe, or contributes to an unsafe condition,
the matter shall be reported immediately to the
designated authority, and the unit shall not be
operated until it has been restored to proper
operating condition.
If, during operation, the loader becomes unsafe in
any way, stop operating the loader and report the
matter immediately to the designated authority. The
loader shall not be operated until it has been
restored to proper operating condition.
Do not make repairs or adjustments unless speci- C. Mounting and Dismounting
fically authorized to do so .
GENERAL RULES AND PRACTICES
The operating rules below should provide a general
list of operator safety considerations. These con-
siderations should be stressed in operator training
and in the preparation of operator manuals.
Warning - Your safety and the safety of those
around you depends upon your using care and
judgment in the operation of this equipment. Know
the positions and functions of aI/ controls before
attempting to operate. D. Starti ng and stopping
All equipment has limitations. Understand the
speed, braking. steering, stability, and load
characteristics of the machine before starting to
operate. Read the Operator's Manual and ask
questions of your supervisor until you know these
limitations.
BE SURE YOU HAVE CHECKED ALL CONTROLS
IN A NON-HAZARDOUS AREA BEFORE
STARTING TO WORK.
The fol/owing are general comments that apply to
aI/ equipment. Review them often as reminders for
proper operation.
A, Personal
E. Machine control check
1. Avoid loose clothing, particularly cuffs and
scarfs.
2. Know what safety equipment is required on
this machine and use it. A hard hat, safety
glasses, reflector-type vests, respirators, and
ear plugs are the types of equipment you may
need.
3. Do not rush.
4. Know the hand signal used on this job and
who has responsibility for signaling.
SO-2
'.~,~,~""
5. It you will be roading a vehicle, know what
warnings must be placed on the machine and
if you will have an escort.
1 . Warn all personal who may be servicing or in
the path of the machine. (
2. Correct or report apparent machine defects.
3. Check to'see all guards, canopies, etc. are
secure and in place.
4. Note all hazards and obstructions such as
ditches, overhead electrical wires, blocks at
wheels, etc.
5. Clean machine floor decks which are clut-
tered or slippery.
6. I nsure proper ventilation for starting indoors.
7. Remove all loose objects stored in or near
the machine.
8. Remove all items which should not be in or on
blade, bowl, bucket, fork, hopper, hook, or
sling.
9. BE PARTICULARLY CAREFUL IF THIS IS
NOT THE MACHINE YOU WOULD
NORMALLY OPERATE.
1. Walk - do not run.
2. Maintain steps and grab irons free of mud and
debris.
3. Never leave the machine unattended with the
engine running.
4. Always lower or secure all equipment before
dismounting.
5. Park in a clear level, authorized area before
(
leaving machine.
6. Do not jump off a machine.
1. Remove or secu re all maintenance or per-
sonal items such as lunch buckets, chains,
shovels, etc.
2. Secure all caps and filler plugs for fuels, oils,
battery covers, and radiators.
3. Know the level in coolant, lubricating oil, and
fuel compartments.
4. Secure seat latch and use safety belt.
S. Always place controls in neutral position
before starting.
6. Observe all gauges to assure the reading are
corrects.
1. Test steering, both right and left, while
moving slowly.
2. Test engine speed control.
3. Test the neutral position to be sure machine
power line can be controlled.
4. Stop and operate all implement controls,
observing feel of lever and smooth response
of implement.
(-
 5. Listen to engine and gear compartments while
moving slowly to determine if there are strange
noises.
6. Observe the exhaust stack, white smoke
indicates water leakage to engine; black
smoke indicates improper fuel control or
blocked air flow; periodic backfire, puffs of
smoke, etc. accompanied by poor power
indicates an engine needing repair.
7. Check funtion of safety devices, lights, backup
alarms, etc.
F. Operation
1. Report any defect in mact"li r"lP not8ci d\ Iring
operation.
2. Observe instruments and gauges frequently.
3. Do not permit riders on the machine.
4. Carry your load so you have maximum
stability while still maintaining ground
clearance.
5. Do not work under overhangs, electric wires,
or where there is danger of a slide.
6. Use extra caution in crossing side hills,
ridges, logs, ditches, etc.
7. Maintain ground speed consistent with ground
conditions. Do not coast.
8. Know and understand the traffic flow
patterns of your job and obey flagman, road
signs or signals.
9. UNDERSTAND MACHINE LIMITATIONS
AND KEEP MACHINE UNDER CONTROL.
( DO NOT TRY TO DO TOO MUCH TOO FAST.
G. Maintenance
1. Do not adjust machine with engine running.
2. Use extreme caution in removing radiator
caps, drain plugs, grease fittings, or pressure
taps.
3. Securely block blade, bowl, etc. when
changing cutting edges.
4. Use safety glasses when pounding with a
hammer. Many machine parts are hardened
and will chip.
5. Do not smoke while fueling.
6. Release all pressure before working on
systems.
7. Block securely when working under machine.
8. DO NOT ATTEMPT REPAIRS YOU DO NOT
UNDERSTAND. THERE IS NO DISGRACE
IN ASKING FOR HELP.

SO-3
 ALWAYS sit in the Seat and fasten your Seat Belt BEFORE starting the Loader Engine!

Read and observe ALL Warnings BEFORE operating this machine!

Keep ALL Guards, Shields and Decals in place and properly secured!

Rest the Attachment (Bucket) on the ground when Loader is NOT in use!

ALWAYS use Lift Arm Stop when Lift Arms are raised for servicing the Loader and remove Ignition Key!

When operating on inclines or ramps, ALWAYS travel with the rear end of the Loader pointed uphill!

Travel slowly over rough terrain and NEVER make sharp turns with the Lift Arms raised.

ALWAYS carry the load low, especially on side hills, inclines and/or when approaching an excavation!

Inspect Hydraulic Hoses and connections on a regular routine basis; escaping fluid under pressure can
cause serious injury!

ALWAYS wear a hard hat when operating the Skid Steer Loader!

Refuel in a safe place away from open flames and potential sparks. NEVER refuel the Loader when the
engine is hot! NEVER refuel with Loader engine running!

The Hydrostatic Drive of a Skid Steer Loader operates with Oil Flow. When the Pump is NOT operating
the Loader can move, especially if stopped on an incline. ALWAYS PARK Loader on level ground with the
c_
point of the Attachment in contact with the ground or park across the incline!

ALWAYS stop the Loader and remove the Ignition Key BEFORE raising Seat Assembly or tilting the
Overhead Guard forward!

ALWAYS mechanically fasten the Overhead Guard to the Loader when tilted forward or in normal
operating position.

DO NOT attempt to clean, adjust, lubricate or service the Loader when any parts are moving!

DO NOT mount or dismount the Loader with the engine running!

DO NOT allow minors to operate or be near the Loader unless properly supervised; Skid Steer Loaders
are single Seat NO passenger maChines!

DO NOT operate the Loader in a closed or confined area; if necessary, adequate ventilation MUST
be provided.

DO NOT leave the Loader with the Lift Arms raised unless the mechanical Lift Arm Stop is positively
engaged.

DO NOT extend your feet beyond the front edge of the Operator's Platform!

DO NOT drive too close to an excavation or ditch!

DO NOTIIHOT ROD" when starting, stopping, turning or reversing Loader directions!

DO NOT exceed Loader rated operating capacity!

SO-4
 CONTROLS & SAFETY Direction of Travel

EQUIPMENT :.
I
~ 't'
STEERING HANDLE CONTROLS (Figs. 1 & 2) / _.... -- rl
(~- ~r--
.~

AWARNING BE SURE to Fasten and Adjust Seat Belts,

and to return both Steering Handle Controls to
their "Neu tral" positions 8 EFORE starting the .~ ~'--

Loader engine. "- --..... r-l

I I I
The Steering Handle controls forward and reverse
motion and turning the Skid Steer Loader. A left Lever Position - Forward
turn is carried out by pushing the right Steering

..
Handle control forward. A right turn is carried out
by pushing the left Steering Handle control forward.
By design and for most efficient use of Loader Direction of Travel
power turns in either direction should only be
carried out with minimal Steering Handle control I I I
I
movement. Forward travel is carried out by pushing
both Steering Handlecontrols forward. Reverse
travel is carried out by pulling both Steering Handle
/
--- -c:. I==r--

controls backward.
Whenever and wherever possible and without
affecting machine operation, Guards and Shields ~. =-
have been used on this equipment to protect "- --..... I
hazardous areas in many places, Decals are also I I I
provided to warn of potential dangers as well as to
display special operating procedures. Lever Position - Backward

AWARNING Read and observe ALL Warnings on the

unit BEFORE operating It. DO NOT operate this

c equipment unless ALL factory installed Guards and Direction of Travel

Shields are properly secured in place.

~
I J
\-___ J
/
.~ ~;--

.~ F=='-
"- --.....
l J I

~
Lever Position - Turn Right
Lever Position - Opposite for Turn Left

Direction of Travel

I I I
Figure #1 Steering Control Handles ~ \--
/
.>- 1"""--

"-
-c:. ~-

...............
I I L
(
Lever Position - Pivot Turn

Figure #2 Operational Handling SO-5

 FOOT PEDAL CONTROLS (Fig.s. 3 & 4) detent is engaged and the pedal will lock in this
position. This supplies constant power to the
The Foot Control Pedal controls raising and lowering hydraulic attachment without manually holding the'
the Load Arms and rolling the bucket or fork forward pedal down. .
or back. Pushing the toe of the Lift Control Pedal forward
from the "Neutral" position lowers the Load Arms. To disengage the Lift Foot Pedal Float position and the ("
Pushing the heel on the Lift Control Pedal down center Foot Pedal position, push the Raise End of
raises the Load Arms. Pushing the toe of the Tilt the pedal down.
Control Pedal forward extends the Tilt Cylinders to
roll the Bucket or Fork forward. Pushing the heel of
the Tilt control Pedal down retracts the Tilt
Cylinders to roll the bucket or Fork back. £ •...
a ~[)
NOTE: The Lift Control Pedal is also equipped with a "/
Float position which is locked in position by
pushing the Lower End of the pedal all the way ~ c: Cl c; ~ f"
forward. The Float position causes oil flow to ~ u q II
effectively bypass the Lift Cylinders thus allowing " IC3

Aux.
the Lift Arms to "Float" while following the ground left
Hyd.
Right
contour.
AWARNING NEVER push the toe of the Lift Foot Extended Forward
Pedal into the Float position when the Load Arms
~-~
~
are raised.
The Center Foot Pedal controls the auxilary power
for the various hydraulic attachments. By pushing
the toe of the center Foot Pedal all the way forward, Figure #3 Pedal Operation

SfiPW'~~f(~rr _
_ ~~r~1kfB

Lower Down
o 0 o ~ ¢ Q.

Lift I Optional I Tilt

Control
Pedal
I Control II Control
Pedal Pedal

o II

Figure #4 Pedal Control

SO-6

•
 LIFT ARM STOP (Figs. 5, 6 & 7)
1\WARNING When it becomes necessary to work on
. . : the Loader with the Load Arms raised, BE SURE

e to use the Lift Arm Stop.

The Lift Arm Stop is located inside the Engine Com-
'!f
. partment Cover. both the "engaged" and "storage",
positions of the Lock are shown. Se.cure the Lock In
the "storage" position with Cotter Pins.

Figure #5 Engine Compartment Cover

( Figure #7 Lift Arm Stop In Use

~ OOOOOOOOO[ SEAT BELT (Fig. 8)

!I 88ggBBBBgB AWARNING BEFORE starting the Loader engine, BE

SURE to fasten and properly adjust the Seat Belt
for a correct snug fit.
Adjust both Belts to obtain the correct length to
I~~======~~~===~$~~~~ match your build and comfort.

! /'L,,, •.
Stop
m 7 ~!.'
Figure #6 Lift Arm Stop In Storage

Figure #8 Seat Belt Fasten

SO-7
 ROLL-OVER PROTECTION-
OVERHEAD GUARD (Figs. 9, 10, 11, 12 & 13)
The Operator's Compartment of the Skid Steer Loader
is protected by a high-strength Overhead Guard. By
removing the rear Overhead Guard Hold Down pins
the guard may be tilted forward for major service work.
AWARNING NEVER operate the Loader with the
Overhead Guard tilted forward. All routine service
and maintenance can be done with the Overhead
Guard in the down and locked position and the Seat
Pan Assembly locked up (Fig. 11 & 12).
For major service work always chain the Overhead
Guard to the Lift Arm preventing it from falling
backward (Figure 13). Seat Plate
Support Cable
DO NOT START THE LOADER WITH THE OVER- (Storage POSItion)
HEAD GUARD TILTED FORWARD OR THE SEAT
ASSEMBLY UP. Figure #11 Seat Plate Up-Cable Assembly

Overhead
Guard Seal

Seat Plate
Suppo" Cable
(LOCK Position)

Figure #12 Seat Plate Locked In UP Position

Figure #9 Overhead Guard

',---

Figure #10 Rear Overhead Guard Pin

Figure #13 Chain the Overhead Guard.
(

SO-8
 IGNITION/KEY SWITCH (Fig. 14)
The Skid Steer Loader is furnished with a Key-type
ignition and Starter Switch. Switch operation and
function is the same as on a car or truck.
( ~\fARNING To prevent upexpected or unauthorized
engine starting, especially while performing service,
BE SURE to remove the Key BEFORE leaving the
Operator's Compartment.
HYDRAULIC/HYDROSTATIC OIL LEVEL DIP STICK
(Fig. 16& 17)
The Oil Level for.the Loader Hydraulics system,'
serving both the Hydrostatic Drives and Lift and Tilt
Cylinders, is visually displayed by a Level Indicator
Dipstick on the front of the machine.

HydrauliC and
Hydrostatic Oil
Level
Dipstick
Cover

Figure #16 Front Cover Hydraulic Hydrostatic Oil Level

Figur.e #14 Right Hand Control Panel

GAUGES (Fig. 14 & 15)

For added convenience in proper routine maintenance a,l Level
Dipstick HydrauliC And
performance, an Hourmeter is provided to automati- ............ ~ Hydrostatic a,l
~ -............ Filler
cally record engine running time. Also provided are

c Hydrostatic/Hydraulic Oil Temperature Guage, Fuel

Level Indicator, Voltmeter, Oil Pressure, and Water
Temperature.
~L~~
THROTTLE (Fig. 15)
Engine RPM is varied with a hand-operated Throttle,
as displayed by the Decal.

CHOKE (Fig. 15)

A hand-operated mechanical Choke is furnished for
Figure #17 Hydraulic 011 Level Dipstick
cold engine starting assistance. Pull the Choke out
to start the engine and push it in all the way after
the engine has reached running temperature.

-~
0,1 ~
Pressure ~
~
--~
----

(
Figure #15 Left Hand Control Panel

SO-9

AWARNINO BEFORE starting the Loader engine and
attempting to operate the Skid-Steer Loader for
the first time, review the WARNINGS section and
~he Controls & Safety Equipment section of this
- manual. Know how to STOP the Loader BEFORE
starting it.
STOPPING THE LOADER
1. Move the Steering Handle controls to the "Neutral"
position.
2. LOWER THE LIFT ARMS to rest onto the Loader
Frame.
3. Place the Foot Pedal Controls in "Neutral" and rest
the Bucket or Fork onto the ground.
4. Move the Throttle to the Idle position.
5. Turn the Ignition Key to "OFF" and remove
the Key.
6. Make sure that all movement and Loader motion
has stopped, detach the Seat Belt and climb autof
the Operator's Compartment.
BEFORE STARTING THE ENGINE
Before actually starting the engine and running the
Loader, familiarize yourself with the Steering Handle
operation to orient your mind and coordinate your
hand movements. Grasp the Steering Handles and
move them in the appropriate directions to simulate
the various movements of the Loader.
operations, Bucket roll-forward and roll-back
operations and combinations of the two functions
before proceeding to operate the Steering Handle'
controls at the same time.
Skill in Skid-Steer Loader operation. is only obtained
th rough proper coordination of the Loader's forward
and reverse travel with raiSing and lowering the
Load Arms and 'v,Vith rolling the Bucket or Fork
forward or back. To gain proficiency, practice all
operations until they happen naturally and without
mistake or hesitation.
AWARNINO Operation of the Skid-Steer Loader at full
Throttle should only be attempted after complete
familiarity with all operations. ALWAYS exercise
caution and good judgement while running this
equipment.
NO TE: To prolong Loader component life, avoid
"jackrabbit" starts, stops and forceful Steering
Handle and Foot Pedal Control movements.
If the Loader engine kills while the Lift Foot Pedal
Control is being opera ted to raise the Lift Arms, the
Lift Arms will stop rising and hold at the level
already reached. Lower the Lift Arms before
attempting to restart the engine. If the Loader
engine kills while the Lift Foot Pedal control is
being operated to lower the Lift Arms, the Arms will
continue to lower until they rest against the Frame.
Return the Lift Foot Pedal Control to "Neutral"
before attempting to restart the engine.

STARTING THE ENGINE BRAKING - STOPPING LOADER MOTION

~ARNINO FASTEN AND PROPERLY ADJUST the Seat The Hydrostatic Drive Pumps of the Skid-Steer
Belt BEFORE proceeding. Loader control braking and stopping Loader
forward and reverse movement. When the Steering
1. Check that both Steering Handle controls are in Handle Controls are moved to the straight "Neutral"
their "Neutral" positions. position, all movement of the Wheels is stopped. By
2. Move the Throttle to the midway point of its travel. all means, BE SURE to move the Steering Handle
3. For cold engine starts, pull the Choke all the way Controls gradually and deliberately to slow-down
out. and stop the Wheels.
4. Turn the Ignition Key to start the engine.
5. Make appropriate Choke readjustments and push
the Choke all the way in after the engine reaches
proper operating temperature.
6. For cold hydrostatic pump engagement, roll
bucket back forcing oil over relief forfast warm up.

FIRST TIME OPERATION

~ARNINO BE SURE that the area being used for test-

running is clear of spectators and obstructions.
Operate the Loader with an empty Bucket or Fork.
Smoothest and most efficient Loader operation is
achieved while the engine is being operated at half
to full Throttle. After the engine is sufficiently
warmed-up, slowly and deliberately move both
Steering Handle controls straight forward. Attempt
all forward, reverse and turning operations before
proceeding to operate the Foot Pedal Controls.
Leaving your hands off the Steering Handle
Controls, slowly and deliverately operate the Foot
Pedal Controls. Attempt all raise and lower

SO-10
 DIGGING AND LOADING (Figs. 18 & 19)

AWARNING ALWAYS lower the Lift Arms down to

contact with the Loader Frame and roll the Bucket
( cutting edge down to contact the ground BEFORE
digging or loading bucket. Failure to do this may
cause damage to Boom and/or Uprights.
Move the loader into the material and, as the engine
RPM loads-down, roll the Bucket back slowly and,
at the same time, gradually pull back on the
Steering Handle Controls to decrease travel speed
while still maintaining Wheel torque. (Fig. 18)
NOTE: Loader working ability is increased when
travel speed is decreased. For optimum working
ability through maximum Wheel torque, move the
Steering Handle Control only a slight amount Figure 18 Digging Bucket
forward, from it "Neutral" position, while filling
bucket.
In most hard-packed materials, to fill the Bucket itis
also necessary to raise the Lift Arms while rolling
the Bucket back. Avoid driving onto the material if
at all possible.
With the Bucket filled, back the Loader away from
the material and rest the Lift Arms down onto the
Frame before proceeding to the dumping area. (Fig.
(Fig. 19)

AWARNINO ALWAYS carry a loaded Bucket or Fork

low with the Lift Arms resting on the Loader Frame.
When operating on an incline or ramp, ALWAYS
travel with the rear end pointed uphill. Figure 19 Loaded Bucket

c
DUMPING THE BUCKET OR FORK
ONTO A PILE (Fig. 20)
Carry the loaded Bucket or Fork low until reaching
the pile. Then, stop forward motion and raise the
Lift Arms high enough so that the Bucket or Fork
clears the top of the pile. Then, slowly move the
Loader ahead to position the Bucket or Fork to spill
the material on top of the pile. Empty the Bucket or
Fork and back the Loader away while lowering the
Lift Arms and rolling the Bucket or Fork back.

Figure 20 Dumping onto a pile

SO-11
DUMPI.NG THE BUCKET INTO A BOX (Fig. 21)
Carry the loaded Bucket or Fork low and approach
the truck, trailer or spreader box squarely with the
side of the box. Then, stop forward motion well
away from the side of the box to raise the Lift Arms
and clear the side of the box. Slowly move the 1
I

Loader ahead to positon the Bucket or Fork over

the inside of the box. After the material is dumped,
back away from the box and lower the Lift Arms
while rolling the Bucket or Fork back.
NO TE: A Bucket can be conveniently used to
spread the pile inside the box by positioning the
Bucket Cutting Edge against the near side of the
pile and rolling the Bucket back while slowly driving
forward and pushing the top of the pile forward.

DUMPING THE BUCKET OVER AN EMBANKMENT

Carry the loaded Bucket or Fork low while traveling
toward the dumping area. Stop the Loader at the
position where the Bucket or Fork extends half-way
over the edge of the embankment. Then, roll the
Bucket or Fork forward and raise the Lift Arms to Figure 21 Dumping into a box
dump the material. After the material is dumped,
back away from the embankment while lowering the
Lift Arms and rolling the Bucket or Fork back.

SCRAPING WITH A BUCKET (Fig. 22)

The Loader should be operated in the forward
direction. First position the Lift Arms at the
appropriate level which allows the Bucket to be
tipped to place the Bucket Cutting Edge at a slight
angle to the surface being scraped. While traveling
c
forward with the Bucket in this position, material
can flow over the Cutting Edge and collect inside
the Bucket.

Figure 22 Scraping with Bucket

LEVELING WITH A BUCKET (Fig. 23)

Leveling with a Bucket attached to the Lift Arms is
best accomplished with a Loader locked into float
position. First drive the Loader to the outer edge of
the area to be leveled. Then, with the Lift Arms
down against the Frame, push the Lift Foot Pedal
control into the Float position and roll the Bucket
forward by pushing the toe of the Tilt Foot Pedal
Control forward to place the Bucket Cutting Edge at
a 30° to 45° angle to the surface to be leveled.
Proceed to level the area by driving the Loader
backwards.

(
'-
Figure 23 Leveling with Bucket

SO-12

•
 BUCKET AND FORK MOUNTING (Figs. 24,25 & 26)
Buckets and Forks are designed for quick and
convenient attachment and detachment. To attach a
Bucket or Fork, approach it from the rear with the
( 1IILift Arms resting against the Frame and the Tilt
.- Cylinders partially extended. Drive the Loader
against the back of the Bucket or Fork head-on and
squarely so that the Attachment Plate in front of the
Lift Arms slides under the Attachment Lip on the
back of the Bucket. With the Lip positively engaged,
retract the Tilt Cylinders completely. Then, shut off
the Loader engine, leave the Operator's Compart-
ment and install the Attachment Pins and Lockpins
in the position shown. To detach the Bucket or
Fork, reverse the process.

AWARNING ALWAYS install or remove the Attachment

Pins and Lockpins with the engine shut OFF and
Lift Arms in lowered position.

( Figure 26 Attaching Bucket

Figure 24 Attachment Pin Location

(- Figure 25 Attachment Pin

SO-13
 LUBRICATION
AWARNINO NEVER attempt to lubricate the Skid
Steering loader with the engine running. Remove
the Ignition Key to prevent unauthorized or
unexpected starting.
GENERAL INFORMATION
NO TE: Properly lubricate the entire Loader and
replace engine oil after the first 50 hours of
operation. Repeat lubrication and oil replacement at
regular 100 hour intervals thereafter. Under more
strenuous operation and/or in extremely cold weather
conditions or dusty conditions, change oil and
lubricate the Loader more often as necessary.
It is well to remember that a sufficient amount of oil
and grease will prevent excessive component wear
and early failure.
ENGINE OIL
Refer to Engine Manual provided for engine oil
requirements and type recommendations. On a daily
basis, check the Oil Dipstick for level indication and
replenish as necessary. Check engine oil hourly
during initial break in of a new engine.
HYDRAULIC & HYDROSTATIC OIL (Fig. 27)
The Hydraulic and Hydrostatic systems share the
same fluid and Reservoir. Reservoir capacity is 9 U.S.
gallons (34.2 liters). Maintain the oil level at
approximately 4" from the top of the Reservoir; DO
NOT overfill as this will force oil out the vent cap and
the fill tube (Fig. 27).
Replace the Hyd rostatic/Hydraulic Oil Filter after the
first 10 hours of operation and at regular 100 hour
intervals thereafter. Replace the Hydrostatic/Hy-
draulic Oil at regular 500 hour intervals or once a
year.
Check the Reservoir level on a routine basis every 10
hours of operation; add oil as required.
Add to or replace Hydraulic/Hydrostatic Oil with
Class S.E. or S.F. 10W40 oil only.
Figure #27 Hydraulic Oil Fill Location
SO-14
SERVICE SCHEDULE
Perform the 'following at intervals indicated or more
often as required. .
DAILY (Every 8 - 10 Hours) (
1. Change Hydrostatic Hydraulic Filter
(Fi rst ti me on Iy)
2. Engine Oil Level
3. Engine Air Cleaner
4. Clean Radiator
5. Engine Fuel Level
(Do not fill when engine is hot)
6. Hydraulic/Hydrostatic Fluid Level
7. Check and Maintain Equal Pressure in All Tires
8. Clean Oil Cooler Fins
9. Check for Oil Leaks
10. Check Wheel Nuts
11. Lubricate All Grease Fittings
EVERY 50 HOURS
1. Inspect tires for Uneven Wear
2. Clean Engine and Hydrostatic Cooling System
3. Clean Engine Air Pre-cleaner. Check Element
4. Drain and Replace Engine Crankcase Oil
(First Oil Change at 50 Hours)
5. ~Iean and Regap Spark Plugs
6. Clean and Inspect Battery
7. Inspect Exhaust System
8. Check Chain Case Lubricant Level
EVERY 100 HOURS
1. Replace Engine Air Cleaner Element.
Clean Pre-Cleaner
3. Replace Engine Spark Plugs
4. Check for Drive Chain Slack
5. Change Hydrostatic/Hydraulic Filter
6. Drain and Replace Engine Crankcase Oil
EVERY 500 HOURS (Or Once A Year)
1. Replace Chain Case Lubricant.
2. Replace Hydrostatic Fluid.
DRIVE CHAINS (Figs. 28 & 29)
Drive Chains run continuously in oil. The oil level
should be checked after every 50 hours of operation
and maintained at a level of approximately 1" deep.
Remove the oil level plug on the chain case side
tank for checking oil (Fig. 29). Replace the Drive
Chain oil every 500 hours of operation. Remove the
Plug on the side of the Loader to drain the oil. Add
to or replace Chain Case oil with Class S.E. or S.F. 30W
by removing the side tank access cover.

Figure #29 Oil Level Plug

Figure #28 Chain Case Cover

KEY TO LUBRICATION
(Grease each fitting every 10 hours)
1. Lift Arm and Cylinder Fittings (Fig. 30)
2. Attachment Pin (Fig. 31)
3. Pedal Fittings (Fig. 32)
4. Control Steering Handle Fitting (Fig. 33)
5. Pump Control Arm Fitting (Fig. 34)

Grease
Fitting Figure #31 Attachment Pin

Figure #30 Lift Arm And Cylinder Fittings

80-15

•
 NOTE: If the Loader ;s operated on a "day-to-day"
basis, it is adviseable to refuel before starting the
day (Fig. 35).

AWARNJNG Refuel in a safe place away from open ('-

flames and potential sparks. NEVER refuel the
Loader while the engine is running or when it "
is HOT.

Figure #32 Pedal Fittings

(~

Figure #35 Fuel FIrJ Locallon

Figure #33 Control Steering Handle Fitting

TRANSPORTING THE LOADER

Avoid driving the Loader from one job site to the
next if any streets or highways are to be used.
Use steel ramps when backing the Loader on a
trailer. Once loaded, chain the machine securely
in place.

Figure #34 Pump Control Arm Fittings

(-

50-16
 SERVICE bottom of the Filler Neck; if NOT, replenish to the
proper level with distilled water.
AWARNING Perform all Loader Service routines with NO TE: Do NO T allow the Electrolyte Solution
the engine shut off, except where noted within specific gravity to drop below 1.200 at 80 F (27 C).
certain procedures outlined.
( BOLT TORQUE DATA
Cleaning Terminals & Cable Connections
The top of the Battery MUST be kept clean. Tighten
the Vent Caps and clean the Battery with a brush
The Chart provided contains information concerning dipped in an alkaline solution (ammonia or baking
standard hardware used on this machine. It is recom- soda and water). After the foaming has stopped,
mended that all fasteners be tightened to the torque flush the top of the Battery with clean water. If
values specified. The Grade of the bolt is identified by Terminals and Cable Clamps are corr0ded,
the markings on the head of the bolt. disconnect the Cables and clean them with the
same alkaline solution.
GENERAL BOLT TORQUE DATA IN FT. - LB.·
AWARNINO Do not allow the alka·line solution to fall
in the Battery Cell. this will result in a dead or
BOLT SAE-GRADE 5 SAE-GRADE 2 weak cell.
SIZE TORQUE TORQUE
Dry Lub. Dry Lub. Jumping a Discharged Battery
%-20 8.00 6.25 5.50 4.17 If Loader Battery becomes discharged and fails to
%-28 10.00 7.16 6.33 4.66 have sufficient power to start the Loader engine,
5/16 -18 17.00 13.00 11.00 8.00 jumper cables can be used to obtain starting
5/16 -24 19.00 14.00 12.00 9.00 assistance.
%-16 30.00 23.00 20.00 15.00
AWARNING DO NOT attempt to jump-start the .
%-24 35.00 5.00 23.00 17.00
Loader Battery If It Is frozen; this may cause It to
7/16 -14 50.00 35.00 32.00 24.00 rupture or explode. Follow these instructions in
7/16 -20 55.00 40.00 36.00 27.00 order and completely as stated to avoid personal
1/2 -13 75.00 55.00 50.00 35.00 injury
1/2 -20 90.00 65.00 55.00 40.00
%-11 150.00 110.00 100.00 75.00 NOTE: BE SURE that the jumper battery is also a
%-18 180.00 130.00 110.00 85.00 12 volt battery.

c * Multiply by (0.1383) for metric kg-m

1. Turn off both ignition keys before making
jumper cable connections.
2. Make sure that both vehicles are in neutral.

AWARNING If acid contacts you skin, eyes or clothing,

flush the area Immediately with large amounts of

o
Grade 2
(Plain)
o
Grade 5
(3 Marks)
water.

3. Interconnect the positive terminals (+) of both

NO TE: The following information is referred to in
both the Troubleshooting .Guide and the Mainten-
ance Schedule sections of this manual. It should
also be understood that a/l services covered in this
section are Owner-Operator responsibilities. Where
indicated, certain service routines should only be
carried-out by an authorized Dealer or Manufactur-
ing representative.
BATTERY
The Loader uses a 12 volt wet cell Battery. The
Loader Electrical System has negative (-) ground.
Adding Water
NO TE: Loaders sold within the United States are
shipped from the factory with Battery installed and
filled with the proper Elec·trolyte Solution.
On a routine basis after every 50 hours of operation,
remove the Battery Vent Caps and inspect the
EI ectrolyte level. The water in the Electrolyte
Solution evaporates at high temperatures or with
excessive charging rates. The level should be to th~
batteries witn on jumpber cabl5.
4. Connect the negative termainal (-) of the booster
battery.
5. Connect the other end of the cable to the
unpainted portion of the Loader Frame or Engine
Block.
NOTE: Twist the jumper cable clamps a couple of
times to make a good electrical contact. DO NOT
short the jumper cables or cross them. The negative
(-) jumper cable connection would NO T be made
directly to the Loader Battery to insure that
potential sparks are kept well away from the
Battery.
6. Proceed to start the Loader. If it does NOT
start immediately. start the engine of the booster
vehicle to avoid excessive drain on the booster
battery.
7. After the Loader is started and running
smoothly, remove the jumper cable from the
Loader Frame member first Then, detach the
opposite end from the booster battery. Then,
remove the other jumper cable from the booster
battery and the Loader positive (+) Terminals.
SO-17
 Allow the loader to recharge the Battery for approxi- 2. Securely block the Loader off the floor (Fig. 37)
mately 10 minutes before attempting to operate the Blocks or jack stands should be placed under the
Loader. Chain Case Side Tanks, both in the front and in .
NO TE: If Loader Battery discharging becomes a the back. Be sure all four tires are off the floor.
reoccurring problem, have Battery checked for 3. Remove wheels and Side Tank Access Covers
possible dead cell and/or troubleshoot Electrical (Fig. 37). (!
System for possible shorted wire or damaged 4. Loosen axle assembly mounting nuts (8 per
insulation. axle).
Recharging Weak Battery 5. Before attempting to tighten or loosen chains, be
sure the axle assemblies are free and not sticking
If LOCider Battery becomes run-down and weak, it
to the gaskets on the Side Tanks. A hydraulic
may be desireable to recharge it with a plug-in 120
jack and a 2" x 4" may be used to hold axle
volt AC battery charger unit. Follow operating
instructions given with recharger unit and exercise assemblies in place while adjusting the tension
(Fig. 37).
all prescribed precautions.
6. Once the proper chain tension is adjusted,
AWARNING DO NOT attempt to recharge a frozen tighten axle assembly mounting nuts to 55 ft. Ibs.
Battery; this may cause it to rupture or explode. of torque and recheck chain tension.
DO NOT attempt to recharge the Battery in an area 7. Replace Side Tank Access Cover, wheels and
of sparks or near an open flame. remove jack stands or blocks from beneath
the Loader.
DRIVE CHAINS (Figs. 36 & 37)
Both Wheels on each side of the Loader are Chain-
driven directly off of independent Hydraulic Motors.
Double Sprockets on the Motor Output Shafts drive
both Wheels through individual Drive Chains which
are running continuously in oil. Drive Chain tension
is adjustable. After every 100 hours of operation,
visually inspect the Drive Chains. Access to the
Chains is obtained by removing the front tire and
the Side Tank Access Cover (Fig. 37). Chain
deflection at the midway point of the chain should
be 1//' with light pressure applied.
Drive Chain Tension Adjustment
Drive Chain Tension must be adjusted if chain
deflection at the midway point of the chain is
greater than %" or less than 1/16" with light pressure
applied.
1. Lower the Lift Arms, stop Loader and remove
Figure #36 Chain Case Cover
Ignition Key.

\,
\\
\1
Axle Assembly 1\

Chain Case
Oil Level Plug

Siock Up
Machine

Axle Assembly
Figure #37 Drive Chain Adjustment

SO-18

•
 ELECTRICAL SYSTEM (Figs. 38; 39 & 40)

Refer to the Wiring Diagram provided for details

(Fig. 40).
NOTE: The System ;s protected by a 20 ampere In-
( l1ne fuse. BE SURE to correct the cause of the Fuse
blowing-out before attempting to replace the Fuse.
Replace the Fuse with a BUSS SFE 20 or equivalent
Fuse (Fig. 39).

Figure #39 Fuse Location Right Hand Instrument Panel

Figure #38 Right Hand Instrument Panel

c lack

A,..-Oi".1nQ
Solenoid

Oil p. ____-
Tem ~ ________

i,
I .
iii" SpJl

1,~
a.~.r
_____ ___ E~IM
____PluQ
_ _ -1I
~011 Wotw

...
""-$I. Temp

------------------------ I

(~ Figure #40 Electrical System

SO-19
£NG"INE (Figs. 41, 42 & 43)
NOTE: Refer to the separate Engine Manual provided
for maintenance, service and adjustment routines.
Air Cleaner \--?~~~~ Engine
Cooler
Check the Air Cleaner on a routine basis every 10
hours of operation. Replace or wash the Filter
Element as necessary.
Alternator -:--"';;'--iiiiiiiir ";"-;';;;;o;n,,~ Hydraulic
Oil
Exhaust System Cooler

The Muffler for the Loader is attached to the engine

Manifold with appropriately-sized Exhaust Pip. Alternator
Belt
Inspect the Muffler and Clamps after every 50 hours Oil
of operation. Dipstick

all
Battery
Crancase oil should be drained and replaced after
the first 50 hours of operation at 100 hour intervals
thereafter. Open the engine compartment cover for
access to the Drain Plug on the bottom left hand
side of the engine. An access hole in the engine
mounting plate is provided for plug removal and
draining. Refer to the Engine Manual for oil
type information.
Figure #42 Engine Compartment

Engone
Compartment

c
COlier

\ Lift
Cylinder
o

Figure #43 Cylinder Location

Figure #41 Engine Compartment Cover

HYDRAULIC SYSTEM
Hydraulic Cylinders
lift and Tilt Cylinders can be conveniently removed
and taken to the Dealer for repair or replacement.
Check Cylinders and connecting Hoses for leaks
after every 10 hours of operation.

AWARNING Lower the Lift Armsonto the Loader Frame

BEFORE attempting to remove a Lift Cylinder.
Allow the Hydraulic oil to cool sufficiently and
relieve pressure BEFORE attempting to remove
Hoses.

Hydraulic System
Refer to the Hydraulic/Hydrostatic System diagram
for details.

SO-20
 0.1
HYDRAULIC & HYDROSTATIC RESERV01R & Cooler
FILTERS (Figs. 44, 45, 46, 47, 48 & 49)
The Hydraulic & Hydrostatic Reservoir & Filters are
shared by both the Hydraulic and the Hydrostatic
Systems' components. The Reservoir fluid level
\Fmr ~ql
\!t
should be constandly maintained at the proper &
operating level. The Filters are located underneath A
the Seat assembly and should be replaced after
every 100 hours of operation. The initial Oil Filter
change is at 10 hours. (Fig. 49) Reservoir oil should
be drained and replaced once a year or every 500
hours of operation. Reservoir level. when properly
filled wi" be approximately 4" from the top.
NO TE: Avoid overfilling the Reservoir.

OIL COOLER (Fig. 48)

I
•
The Oil Cooler is mounted behind the engine
compartment cover and is accessible by unlocking Figure #45 Power Hydraulic System
the engine cover lock (Fig. 41). Check the Oil
Cooler for leakage and clean it of any dirt or debris
build-up on a routine basis after every 10 hours of
operation.

AWARNING Never leave the Loader running when

attempting to raise the Seat Assembly. The
Steering Handle controls may be bumped in the
process causing the Loader to lunge forward.
Allow the Hydraulic Oil to cool-off BEFORE
attempting to clean or service the Cooler.

AWARNING Never Start the machine with the Seat

Assembly raised up and locked or with the

c
Overhead Guard tilted forward when checking
for leakage.

Hydrostatic
Motor
Figure #46 Hydrostatic Motor System

lilt
Cylinder L ~, rC7 "=='/"
~
\
~:l'/
•..
.
//
. /// /
,//

.LL./)b
\~
I

I
I

~.c.,
.~
~~
'" -'=======t
Figure #44 Lift Arm Hydraulic System

c. Figure #47 Hydraulic Filter Location

SO-21

•
 Overhead
G"".,,,

o.~rI'l~aC:
~7'
Guar::: Sea' (
Sc.DDO-: Sr"c Overhead
Guard
Stop

Se~: Prare
SUDDor- Caore
fLock POSition)

~-------J
\
Figure #48 Lock Seat

SEAT ASSEMBLY (Fig. 48) Figure #50 Overhead Guard

Ti'le Seat Assembly can be raised and locked in up

position for clearance to perform service or
adjustment in the areas of the Hydrostatic pumps,
engine or Steering Handle Control Linkages to th'3
Fumps (Fig, 43).

Figure #51 Rear Overhead Guard Pin

\

---
Figure #49 Hydraulic Filter

OVERHEAD GUARD (Figs. 50, 51 & 52)

The Overhead Guard can be conveniently detached
and tilted forward (by two men) from the Loader for
additional clearance to perform service or adjustment
in the areas of the Hydrostatic Pumps, Engine,
Hydrostatic Motors or Linkages to the Pumps.
Unfasten and remove the (2) mounting bolts in the
rear securing the Guard to the Loader Frame. Then,
carefully raise the Guard to and tilt forward on the
Loader (Fig. 50, 51 & 52).

~ARNING BE SURE to replace and tightly secure the Figure #52 Raising Guard Forward and Chained
Overhead Guard BEFORE operating the Loader.

SO-22
 SYSTEMS CONTROL VALVE
The Loader is equipped with a 3-Spool Systems
Control Valve which has an Auxiliary Output
Control Linkage connection.
( Repair
NOTE: Systems Control Valve removal and service
should only be carried-out by your Prime-Mover
dealer.
Maintenance
The Systems Control Valve is mechanically
maintenance free requiring only that it be operated
with properly filtered and routinely changed oil.
Mechanical linkages should always be kept properly
adjusted and tightly secured. Hydraulic Hose
connections should also be checked frequently to
insure leak-free condition.
SYSTEMS PUMP
The Systems Pump is driven directly oft the
Hydrostatic pump shaft and provides hydraulic
pressure and oil flow to the Systems Control valve.
Repair
NO TE: Systems Pump removal and service should
only be carried-out by your Prime-Mover dealer.
C~
Right Hand
Motor
Control
Valve
Q
Control
Pedals
Left Hand
Motor
Figure #53 Hydrostatic Motor And Pump
Maintenance
The Systems Pump is mechanically maintenance
free requiring only that it be operated with properly
filtered and routinely changed oil. Hydraulic Hose
connections should be reoutinely inspected and
kept tig htly secu red and leak-free.
HYDROSTATI~ PUMPS & MOTORS (Fig. 53)
Pumps
The Front Hydrostatic Pump, controlling the left
Drive Motor for the left side Wheels and the Rear
Hydrostatic pump, controlling the right Drive Motor
for the right side Wheels. are coupled to and driven
by a common Drive Shaft off the engine Output
Drive Shaft (Fig. 53).
Repair
NOTE: Hydrostatic Pump and Motor and removal
and service should be carried-out by your
Prime-Mover dealer.
Maintenance
The Hydrostatic Pumps and Motors are
mechanically maintenance free requiring only that it
be operated with properly filtered and routinely
changed oil. Mechanical linkages should always be
kept properly adjusted and tightly secured.
Hydraulic Hose connections should also be checked
frequently to insure leak-free condition.
Trunnion Shaft
Connecting Rod
Hydraulic Oil
Filters
SO-23
NEUTRAL CONTROLS (Figs. 54 & 55)
NOTE: The Left Neutral controlling the front
Hydrostatic Pump and the right Neutral controlling
the rear Hydrostatic Pump provide the mechanical
linkage between the Steering Handle Control and
the Hydrostatic Pump, (Fig. 54). The Left Neutral is
clamped on the Front Hydrostatic Pump Trunion
Shaft. The Right Neutral only pivots on the Front
Hydrostatic Pump Trunnion Shaft and is fastened to
the Rear Hydrostatic Pump Trunnion Shaft (Fig. 54).
The Neutral Controls must be centered to prevent
the Loader from creeping forward or backward
when the Steering Handle sare in the neutral
position and to provide for straight forward and
backward travel when the Steering Handles are in
their full stroke position.
Repair
Neutral Control removal and service should only be
carried-out by your Prime-Mover dealer.
R'9nl Hilnc
N"ulra l ASSemOly
Neutral ContrOl
SlOP
Figure #54 Neutral Controls
Figure #55 Neutral Control Side View
SO-24
Maintenance
The Neutral Controls should be greased at the
various contact point.s (Fig. 55) and the proper
adjustments made to the neutral stops and neutral
centering Ii nkage.
Neutral Control Stop Adjustment (Fig. 56)
(
If the Loader at the full stroke Steering Handle
position veers off the straight Ii ne of travel, the
Neutral Control Stop must be adjusted.
1. Lower the lift Arms, stop the Loader and remove
the Ignition Key.
2. Raise the Seat Assembly up and lock in position
(Figs. 11 & 12). The Loader must never be
running when the Seat Assembly is raised or
when adjustments are made.
3. Ajustments can be made to either increase the
speed of the slower set of wheels or decrease the
speed of the faster set of wheels. Locate the
Neutral Control Stops on each of the Neutral
Controls
4. To decrease forward travel loosen lock nut on rod
end and turn linkage rod into Rod End. To
increase forward travel loosen lock nut on rod end
and turn linkage rod out of Rod End (Fig. 56).
5. To decrease backward travel, loosen locknuts (2)
on linkage rod, move away from Rod End and lock.
(To increase backward travel, loosen locknuts (2) on
linkage rod, move toward Rod End and lock (Fig. 56).
6. Re-tighten locknuts before lowering Seat Assembly.
Replace Ignition Key, Fasten Seat Belt, start
Loader and check Loader for Straight line of travel. (
7. Follow procedures 1 through 6 if more adjustments '_
are necessary.
Neutral Centering Adjustment (Fig. 57)
If the Loader creeps in either direction when the
Steering Handle Controls are in neutral position, the
Neutral Centering Adjustment must be made.
1. Lower the lift Arms, stop Loader and remove the
Ignition Key.
2. Raise the Seat Assem bly up and lock in
position (Fig. 48). The Loader must never be
running when the Seat Assembly is reaised or
when adjustments are made.
3. Locate the Neutral Centering Adjustment Rod
on the top of each Neutral Control (Fig. 56).
4. To stop one set of wheels from creeping
forward, loosen the locknut and lengthen the
Adjustment Rod, which moves the Neutral
Control backward. To stop one set of wheels
from creeping backward, loosen the locknut
and shorten the Adjustment Rod which moves
the Neutral Control forward (Fig. 57).
5. Re-tighten locknuts before lowering Seat
Assembly. Replace Ignition Key, Fasten Sea
Belt, and Start the Loader. With the Steering
Handle Controls in the Neutral Position check
the Loader for creeping.
6. Follow procedures 1 through 5 if more
adjustments are necesary.
•
 AWARNINO. Never leave the Ope-rators Compartment
with the Loader running even If the Steering
Handle Controls are in the Neutral Position and the
Loader is stationary. The Neutral Position on the
Loader is an operating convenience only and not
( meant for unattended parking.
Figure #56 Neutral Controlling Rods
c NO Tire can be moved to the other side of the
Figure #57 Adjusting Rod
WHEELS & TIRES
Loaders are. available with two variations of Wheels
and Tub(ess Tir~ sets: standard set is compos~d of
7.00 x 15 6 ply Tires on 15.00 x 6 Wheel Rims or,
optional set is composed of 10 x 16.5 8-ply Flotation
Tires on 16.5 x 8.25 Wheel Rims. Loader operation
and proper operation is dependent upon routine
maintenance .of the Wheel and Tires. Beyond repair
of the Tires due to damage from operating hazards,
such as nails, sharp rocks, etc., the following
guidlines should be closely complied with.
Tire Pressure
Proper equal and maintained Tire pressure is
essential to long life, even wear and operating
stability. The standard 7.00 x 15 6-ply Tire pressure
should be checked after every 10 hours of operation
and maintained at 50 psi. The optional 10.00 x 16.5
8-ply Flotation Tire pressure should be checked
after every 10 hours of operation and maintained at
40 psi.
Tire Wear & Rotation
Proper function of the Loader is greatly dependent
upon the design and orientation of the Tire Tread
and direction of rotation. Treads are angled toward
the centers of the Tires and MUST be mounted on
the Wheels, and, in turn, on the Loader so that their
angles and rotations are forward on all four Wheels.
These important factors limit Tire Rotation, without
Wheel changing, to only interchanging the front
Tire on one side with the rear Tire on the same side
of the Loader. Without switching Tires with Wheels,
Loader.
NO TE: To prevent damage to the Drive Motor and
Drive Chains, it is highly recommended that both
Tires on one side of the Loader are changed at the
same time even though one Tire's Tread is badly
worn. This replacement of both Tires is necessary
to equalize the loads on both Chains which are
driven off the same Double Sprocket and Drive
Motor.
Wheel Nuts
Wheel Nuts MUST BE checked after the first 10
hours of operation and at regular 50 hour intervals
thereafter. Check that all nuts are torqued to
65 ft.-lb.
SO-25
 Power Controls
-------------,
I
I
I I
I I
I I
I
I
I
I
1_-
Figure #58 Hydraulic Schematic

C
<t>
-<I>-
Cooler

Filter
+
rt-
Hydraulic
Lines
Cros:;mg

Hydraulic
Lines
Joining

--()- Check Valve W Reservoir

Female
----c;H Coupler

Male
----7-t Coupler
Cylinder

1- ---1 Component
Enclosure
,----j

Q Pump
0 Engine
Enclosure

~ Control lever

Figure #59 Hydraulic Schematic

(-

SO-26
 TROUBLESHOOTING
GENERAL
( Symptom
Loader Hydrostatic or
Hydraulic systems overheated.
General operations sluggish.
Hydraulic system NOT
responding at al\.
c
HYDROSTATIC DRIVE
Loader will NOT move in
either direction.
Wheels on one side of Loader
do NOT move at all while other
side Wheels move correctly
forward or back.
•
Possible Cause
Oil Cooler restricted or NOT
functioning properly and
restricting air flow.
Both Hydrostatic Pumps
overloading.
Systems Pump overloading.
Air in the Hydraulic System.
Engine NOT responding to loads. Reset engine characteristic; see
Oil Leaking somewhere in the
system (possibly internally).
Engine/Systems Pump Drive
Coupler deffective.
Systems Pump defecti"o.
Oil level is too low.
Steering Linkage Rods are
disconnected.
Drive Coupler broken.
Side with Wheels NOT turning
has either a Hydrostatic Pump,
Drive Motor or Drive Chain/
Sprocket breakdown.
Pump Arm for side of Loader
with Wheels NOT moving is
loose, broken or disconnected.
Remarks
Clean the Cooler and inspect for
damage. blockage or improper
functioning and contact dealer for
additional di rectives.
Steering Handle being improperly
operated. Refer to Operation
section for correct procedures.
Foot Pedal Controls being
improperly operated. Refer to
Operation section for correct
procedures.
Purge air; check Oil Level Indicator
and replenish (if necesary).
Engine Manual.
Contact dealer for additional
directives.
I nspect and contact dealer for
addtional directives.
Contact dealer for additional
Check and replenish if necessary.
Check connections and reconnect
if loose.
Contact dealer for additional
directives.
Inspect Drive components for that
side to determine problem and
contact dealer for additional
direct i ves.
Correct Pump
Correct Pump Arm problem.
SO-27
Symptom
HYDRAULIC DRIVE
Hydraulic cylinder action
is slow.
Lift Arms do NOT maintain a
raised position when the Foot
Pedal is moved to "Neutral" or
Load Arm operations are
occuring very slowly.
Bucket or Fork drifts downward
(rolls slowly forward) with Foot
Pedal in "Neutral", or Bucket
roll forward or roll back
operation occurs very slowly.
Lift Arms will NOT lower.
Jerky Lift Arm or Bucket action.
SO-28
Probable Cause
Low engine RPM.
Oil is too heavy.
Oil is leaking past cylinder
packing.
Systems Valve Spools are NOT
opening completely.
Systems Pump is
malfunctioning
Oil is leaking past Control
Spools.
Leakage of oil past Seals in
cylinder.
Spool NOT Centered in Valve.
Oil is leaking past Control
Spools.
Leaking Fittings or Hoses.
(See immediate preceding causes and remedies)
Lift Arm Lock engaged.
Air in Hydraulic System.
Low oil level in Reservoir.
Sticking Systems Control Valve.
Remarks
Increase engine RPM. (
Allow oil to warm-up by rolling
bucket back and forth and going
over rei ief.
Check packing condition and
a-rings and replace if worn
excessively.
Adjust Linkage Rod lengths for a
f u lI'i~" S P00; t ra \/ e i.
Contact dealer for troubleshooting
directives.
Valve Housing or Spools defective;
. contact dealer for repai r.
Check and replace Seals.
Adjust Foot Pedal Linkage Rod
length or repair Valve Spool with
dealer's directive.
Valve Housing or Spools defective;
contact dealer for repair.
I nspect Tighten or replace as
necessary.
Release Lock.
Cycle the Cylinders and maintain
full-pressure for a short time to
purge the air.
Check Level Indicator and replenish.
Contact dealer for further directive.
 Symptom
ELECTRICAL SYSTEM
( Engine will NOT turn over.
En9ine turns over but will NOT
s£an.
Engine Overheating
Incorrect engine timing
C Shrouding on engine is
Probable Cause
Battery conections loose or
corroded.
Battery discharged or defective.
Interconnection wires loose.
Ignition switch, regulator,
solenoid and/or starting
motor defective.
No fuel in Tank.
Battery is w~aK.
Fuel is NOT reaching
Carbu retor.
Crankcase oil supply is too low
or overfilled.
Engine is overloaded.
Engine Cooler is blocked.
Air circulation is restricted.
Exhaust System is restricted.
Dirty or improper grade oil.
Dirty or improper grade oil.
Incorrect engine timing
adjustment
removed.
Remarks
Clean Terminals or Cables and
tighten them securely.
Recharge or replace Battery.
Troubleshoot and inspect wiring.
Refer to Engine manual or check
with dealer for additional
assistance.
Refuel.
Usc ,J urnper (;a~Ic;.s ui recha(ge
Battery.
Inspect Fuel line for blockage
and remove.
Add or drain oil as necessary.
Increase engine RPM with Throttle.
Service Cooler ..
Remove dust, dirt or blockage.
Remove restriction.
Drain and replace with correct
Drain and replace with correct
grade of oil.
Readjust timing per Engine
Manual.
Replace Shrouding.
SO-29
 8 r
K

~--D----t~

~~---------J--------~

~--------------A ----------------~~

r- N
SPECIFICATIONS
A. Overall Length w/Bucket 113.00 (2870)
B. Overall Height w/Guard 79.75 (2019)
C. Ground Clearance 8.00 (203)
D. Wheel Base 35.00 (889)
E. Dump Hieght 91.50 (2324)
F. Reach @ Max. Height 15.00 (381)
G. Reach @ Spec. Height 32.50 (826)
H. Specified Height 34.00 (864)
I. Height to Hinge Pin (Max.) 114.00 (2896)
J. Overall Length-Less Bucket 89.00 (2261)
K. Overall Height 60.00 (1524)
L. Dump Angle 37°
M. Angle of Departure 28°
N. Bucket Width 55.00 (1397)
O. Clearance Circle Front-Less Bucket 41.00 (1041)
P. Clearance Circle Front-Width Bucket66.00 (1676)
Q. Clearance Circle Rear 52.00 (1321)
R. Overall Width-Less Bucket 54.00 (1372)
S. Tread Width 46.00 (1168)
( ) in centimeters

.....---s--~
- - - - - - R -----1~
SO-30

•
 SPECIFICATIONS
Engine Transmiss'ion
Manufacturer Chrysler Pump (Sundstrand series 18) 0-2.3 cu in
( Model H-98
4 Motor (Ross TRW MAE24029)
(37.6 cm 3)
20 cu in (320 cm 3 )
Cylinder
Cycle 4 Stroke Filter .10 micron replaceable cartridges two
Bore 3.43" (87.3 mm) Charge pressure setting 100 PSI min @ 1800 RPM
Stroke 2.62" (66.3 mm) Nut on drive sprocket 300 ft.ll bs. - dry
Displacement 97.5 (1598 cc) Final Drive
Speed - Fast (no load) 2800 RPM Wheel Spindles Normal
, _t
• -
I
i
~
~
'
\
.....
I -,.~
~ r -f \
• __ --~i
~ "X' !""''")H 55 ft lbs
" ••'j""' "., -" .. j

Horsepower (manf. rating @ RPM) 35 @ 3000 RPM Reductions 10:37

Valve Clearance - intake (cold) .010 (.254 mm) Travel Speeds
Valve Clearance - exhaust (cold) .016 (.406 mm) Forward and Reverse 6.5
Spark Advance 10°
Hydraulic System
Spark Plug RN9Y Champion
Pump - Make Borg Warner
Capacities Pump - Model 515 S-9-D-H-1-2-R
Fuel Tank 13.4 Gal (51.00 I) Pump - Output 6.8 GPM 1800 RPM (25.7 LPM)
Hydraulic Reservoir 9.0 gal (33.93 I)
Pump - Displacement
Cooling System 9.6 gal (49.1 I)
Oil Temperature
Crank Case w/Filter 4.0 qts (3.7 I)
Suction Screen
Lubricants
Control Valve
+120° F to +10° F SAE 20W-40 Victor, 3 spool open center
Valve - Make
+80°F to -10°F SAE 10W-40 series, internal circuitry for
+60° F to -40° F SAE 5W-40 simultaneous operation detent for
( Electrical System
Battery 3ET -75 Amp - Hr.
float position in boom lift and
auxiliary circuits, relief pressure
Rating 90 2200 PSI (154 kg/cm3)
Starter Switch Key Activated Solenoid Boom Cylinders
Ignition Battery Double Acting - 2" (5.1 cm) 26" stroke (66 cm)
Alternator Capacity 41 Amp
Bucket Cylinders
Regulator Solid State
Double Acting 2" (5.1 cm) 16.5 stroke (41.91 cm)
Rectifier Solid State
Spark Plug Gap .030 (.762 mm) Oil Filter
Spark Plug tightening torque 25-30 ft.!lbs. 10 Micron (2 per machine)
(3.4-4.1 m m/kg.) Area 860 in 2 (5548.00 cm2) total
Light Circuit Protection Fuse - 20 Amp Blocked By-Pass
Ignition System Protection ,Fuse - 20 Amp Replacement Cartridge

Fuel System
Type of Fuel Regular Gasoline
Cleaning System Replaceable Inline Filter
Air Cleaner
Dry Type Filter

SO-31
 ®

PRIME-MOVER
THE PRIME-MOVER CO. I MUSCATINE, IOWA 52761 (~
DIVI~ION, HON INDUSTRIES
 Service Bulletin

This service bulletin is to assist Prime Mover L 1200 Diesel skid steer loader owners
\vith parts and service infom1ation.

This portion of the L 1200 parts manual has purposely been recopied with corrections
and additions made to help customers order parts for their L 12000. Pay close attention to
the notes made on each diagram. They wi II contai n the part numbers and part
descri ptions.

We apologize for the crudeness used in putting this infonnation together. Hopefully in
the future \ve \vill be able to put together something a bit more creative.

(-
 FIGURE 1 OVERHEAD .GUARD ASSEMBLY ,.

~1--27
2 26 V
~.I
25

3~
36

33 34 35 38
Iii'"
30
38
..,.'
{; 1- f
I

-(~ ~..
~
,-~
__...
'/d.
L-v -/-:;
I

t-.

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Fig. Item # Fig. I t e m ' #
# # Part # Name Assy. # # Part # Name Assy.
1 1 03594018 Gasket, Top 2 1 22 04199015 Gauge, Oil Pressure 1
1 2 02719013 Screen, Top 2 1 23 03422029 Panel Assembly L.H. 1
1 3 03594026 Gasket, Bottom 2 1 24 03170016 Cable, Choke 1 - I«/V'
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,
1 4 02718015 Screen, Bottom 2 1 25 02427012 Guard, Overhead 1
1 5 02240018 Seat Assembly 1 1 26 03561015 Lamp, Head .8-/lf f66 -/ 2
1 6 92715013 Nut 2 1 27 03566017 Lamp, Rear I?- / 'T ft.? - ,. 2
1 7 91801516 Screw, Cap 2 1 28 01948017 Pin Cotter 2
1 8 01148023 Belt, Seat 1 1 29 02791011 Pin, Overhead 1
1 9 02563014 Pan, Seat 1 1 30 02195015 Mount, Rubber 4
1 10 91203762 Nut 4 1 31 03592012 Washer 4
1 11 91801300 Screw, Cap 4 1 32 02026054 Strip, Foam 2
1 12 02673011 Meter, Hour 1 1 33 03086031 Seal, Floor Pan 1
1 13 03401015 Meter, Volt 1 1 34 03086023 Seal, Floor Pan 2
1 14 04200010 Gauge,Water Temp. 1 1 35 04192019 Pan, Floor 1
1 15 03359016 Clamp 1 1 36 P-11894-15 Screw, Cap 2
1 16 02179019 Switch, Ignition 1 1 37 P-11261-10 Nut 2
1 * 02179027 Key 2 1 38 02698027 Spacer 4
1 17 03422011 Panel Assembly ~ ~ 1 1 39 P-11045-1 Screw, Cap 2
(- 1
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18
19
03580017
03169019
Switch, Assembly
Cable, Throttle _
1
1
1
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40
41
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Bolt, Flange
4
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1 20 02672013 Meter, Oil Temp 1 1 42 02243012 Screw, Throttle ~ 2
1 21 02671015 Gauge, Fuel Level 1 wI '1

SP-1
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Radiator Core Size Radiator Core Size

17¥. x 20Yl x 1'14 15Yl x 20Y. x 2

Fig. Item # for # for

# # Part # Assy. Part # Assy. Name
2 1 P-11170-6 4 P-11170-6 4 Nut, 3/8
2 2 P-11016-3 4 P-11016-3 4 Washer, 3/8
2 3 04026010 1 04352019- 1 Cooler, Oil
2 4 01992032 4 01992032 4 Bolt, Flange, 3/s.75
2 5 93000067 2 93000067 2 Nut
2 6 01990010 3 01990010 4 Nut
2 7 91801772 2 91801n2 2 Screw, Cap
2 8 04092011 1 Not Used Bracket, Cooler/Radiator
2 9 04178019 1 Not Used Bracket, Cooler/Radiator
2 10 04125010 1 04125010 1 Cap, Radiator
2 11 52-5065 As Req. 52-5065 As Req. Hose, Radiator
2 12 04001012 1 04351011 1 Radiator
2 13 94040012 1 94040012 1 Cock, Drain
2 14 04177011 1 04356011 2 Strap

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 Fig. Item # for # for
# # Part # Assy. Part # AssY· Name
2 15 04002044 1 04358017 1 Hose, Radiator
C- 2
~
16
17
B-14859-5
0400403'6
4
1
B-14859-5
043P7019
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Clamp, Hose
Hose, Radiator
2 18 B-14857-2 2 B-14857-2 2 Clamp
2 19 04201018 1 04201018 1 Hanger, Muffler
2 20 04164018. 1 04164018 1 Muffler
2 21 04191011 1 04101011 1 Pipe, Extension
2 22 04005014 1 04005014 1 Shroud, Radiator
2 23 VB4241073 1 VB4142315 1 Belt, Gov. Drive-Bates #7280
2 24 VB4027314 1 VB4027314 1 Belt, Altr. Drive-Gates #7430
2 25 B-14859-4 4 B-14859-4 4 Clamp, Hose
2 26 VB4142315 As Req. B-14423-15 As Req. Hose
2 27 04180014 1 04180014 1 Intake, Carburetor
2 28 04196011 1 04196011 1 Clamp, Muffler
2 29 RN9Y 4 RN9Y 4 Plug, Spark
2 30 04113015 1 04113015 1 Engine, ChrYsler
2 31 A-14831-1 4 A-14831-1 4 Clamp, Hose
2 32 01158014 1 01158014 1 Filter, Fuel'
2 33 52-5052 As Req. 52':5052 As Req. Hose, Fuel
2 34 04168010 1 04168010 1 Mount, Engine ~

2 35 04163010 1 04163010 1 Plate, Flex

2 36 04162012 1 04162012 1 Housing, Bell
2 37 04167012 1 04167012 1 Brac~et, Electrical
2 38 NA NA Cap, Bell HOLtsing
2 39 Transmission Assembly (See Fig.#6)
2 40 04011011 2 04011011 2 Mount, TE?P9~ie~ieA &nt.g~
2 41 04182010 1 04355013 1 Mount, Radiator
2 42 P-11045-2 4 P-l1045-2 3 Bolt, Flange V4 x.50
2 43 P-11261-14 4 P-11261-4 4 Nut V4
C 2
2
2
44
45
46
P-l1009-8
P-l1009-6
P-11143-8
2
2
2
P-ll009-8
P-ll009-6
P-1143-8
2
2
2
Lockwasher V2
Lockwasher 3/a
Screw, Cap 31a x 2
2 47 03585017 2 2 Nut 112 Top Lock
2 48 P-11854-3 6 P-11854-3 6 Screw, Cap 5A6 x .75
2 49 P-l1009-5 6 P-11009-5 5 Lockwasher SA 6
2 50 P-11854-10 1 P-11854-10 1 Screw, Cap 5A6
2 51 P-11016-2 1 P-11016-2 1 Washer, Flat 5A6
2 52 04237013 1 04237013 1 Filter, Oil Element
2 04321014 1 Shroud, Air
I

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 FIGURE 9 CONTROL COMPONENT WIRING

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Fig. Item # for
# # Part # Name Assy.
9 1 Harness Assembly (See Fig. 10) . 1
9 2 02675017 Sender, Fuel - ()~ O;L6 750;;l ~ 1
9 3 02676015 Sender, Oil Temp. 1
9 4 04174017 Harness Assembly 1
9 --- 5 Valve Assembly (See Fig. 19) 1
9 6 P-25332-1 Tie, Clamp 1
9 7 20 Amp Fuse (secure this part locally) 1
9 8 02179027 Key 2
9 9 02179019 . Switch,lgnition 1
9 10 02673011 Meter, Hour 1
9 11 03401015 Meter, Volt 1
9 12 04200010 Gauge. Water Temp. 1
9 13 04174025 Harness Assembly 1
9 14 04199015 Gauge. Oil Pressure 1
9 15 02671015 Gauge. Fuel Level 1
9 16 02672013 Meter, Oil Temp. 1

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 FIGURE #19 ENGINE COMPONENT WIRING

SPL-1300 42 PRIME-MOVER JUNE 1986

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 Fig. Item # For
# # Part # Name Assy. Unit

( 19 1 04983-00 Sender, oil temp. 1

19 2 04927 -00 Harness, wiring - 1
19 3 A-49794-00 Switch, neutral 2
19 4 C-20163-66 Wire assembly 1
19 5 NSS Starter, engine 1
19 6 04983-00 Sender, water temp. ,-/ 1
19 7 NSS Alternator, engine 1
19 8 NSS Sender, oil pressure- 1
19
19
19
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11
02675017 Sender, fu 11 le~el ~;; __ I- It
NSS- Q 5"<i«doq Regulator l~ql.l~O'i).-5~1O ~ ~ Id).t/t:(
NSS Plugs, glow ~wd'-d....L./~-d
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19 12 NSS Jumper ,'. . 1

pm ?I b{,f(;f(;OO'j

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JUNE- 1986 PRIME-MOVER SPL-1300 43
( )
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 FIGURE 120 POWER COMPONENT WIRING

SUPPLIED WITH
ENGINE

SPL-1300 44 PRIME-MOYER JUNE 1986

( )

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 Fig. Item # For
# # Part # Name Assy. Unit

( 20
20
1
2
B-49808...;06
NSS
Cable, positive
Boot
1
1
20 3 B-49807-06 Cable, negative 1
20 4 NA Battery, 12 volt 1
(Secure this part locally)
(Group 24 - 475 AMP)

JUNE 1986 PRIME-MOVER SPL-1300 45

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 TorqmQtor™
MAB and MAE Series Service Procedure
.' • : ... ,.' .'" ...,. .... " .. ".l ._ • . • ...v :. . .....
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Ross Gear Division

(
Price $3.00
(~
 " '

Table of Contents
Page

Trouble Shooting Guide ....................................................... 1A

Exploded Assembly View Fold Out. ..... '....................................... 1S, 1C
Trouble Shooting Checklist ..................................................... 10
Seal Installation Tools ................................' .......................... 2
: MAS Service Parts list Chart .................................................... 3
(1 y, Inch, 31.8 mm, Seal Dia. Coupling Shaftl

MAE (Standard! Service Parts list Chart ............................... , ............. 4

(B'. Inch, 31.8 mm, Seal Dia. Coupling Shaft)

MAE Service Parts list Chart .................................................... 5

1Yz Inch, 38.1 mm, Seal Oia. Coupling Shaft)
Disassembly & I~spection ....................................................... 6
Assembly .................. " ....... , ....................................... 8
c~
Final Checks ........ : ....................................................... 10
Hydraulic Fluids ....... : ...................................................... 10
Filtration, Operatlng'Temperature ................................................. 10
Tips for Maintaining the System ................................................. 11

© TRW Inc .

... _-._---_ ... __ ._ .. _-----_.. ---- - -'.' • ,. • __ • • • • - eo •••. ••••• _ . _ _ _ _ _ _ . . . . . . . . . . . . . . . . . _ _ _ _ _ - - - _ • • • •

 Troubleshooting Guide
NOTE: Before troubleshooting any system problem, check service literature pubtis.hed
by the equipment and/or component manufacturers. Follow their instructions, if given,
for checking any component other than the MAB or MAE Torqmotorrw unit.
Preparation
Make your troubleshooting easier by preparing as follows:
• work in a clean, well-lighted place;
• have proper tools and materials nearby;
• have an adequate supply of clean petroleum-based solvent.
WARNING: SINCE THEY ARE FLAMMABLE, BE
EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN
A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR
DEATH.
WARNING: WEAR EYE PROTECTION AND BE SURE TO
COMPLY WITH OSHA OR OTHER MAXIMUM AIR
PRESSURE REQUIREMENTS.
Preliminary Checks
Hydraulic systems are ohen trouble-free. The problem an
operator complains of could be caused by something other
than the hydraulic components.
Thus, once you have determined that a problem exists, start
with the easy-to-check items, such as:
• parts damaged from impact that were not properly
repaired, or that should have been replaced; and
• improper replacement parts used in previous servicing
• mechanical linkage problems such as binding, broken, or
loose parts or slipping belts.
------------ ._--_._--- ._---------- ----
(
Hydraulic Comp~nents
If you think the problem is caused by a hydraulic component,
start by checking the easy-to-reach items.
Check all hoses and lines for cracks, hardening, or other signs
of wear. Reroute any useable hoses that are kinked, severely
bent, or that rest against hot engine parts. Look for leaks,
especially at couplings and fittings. Replace any hoses or lines
that don't meet system flow and pressure ratings.
Next, go to the reservoir and filter or filters. Check fluid level
and look for air bubbles. Check the filter!sl. Afilter with a
maximum 50 micron filtration is recommended for the MAS
and MAE system.
Visually check other components to see if they are loosely
fDounted, show signs of leaks, or other damage or wear.
Excessive heat in a hydraulic system can create problems that
can easily be overlooked. Every system has its limitation for
the maximum amount of temperature. Aher the temperature is
attained and passed, the following can occur:
• oil seal leaks
• loss of efficiency such as speed and torque
• pump loss of efficiency
(
• pump failure
• hoses become hard and brittle
• hose failure
A normal temperature range means an efficient hydraulic
system. Consult the manuals published by equipment and/or
component manufacturers for maximum allowable temperatures
and hydraulic tests that may be necessary to run on the
performance of the hydraulic components. The MAS and MAE
are not recommended for hydraulic systems with maximum
temperatures above 200 OF 193.3 OCI.
lA
...•...
 " "
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'....::..:

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NOTE: Assomblu SIIIII Flat Sido Out as Shown in Enlarged.

Villw of SlIctioned Segments of Items NUlllber 19 and 20.

Item
No. Description
l. Seal 14. Drive link
2. Autaining Ring 15. Wear Plate
3. Back·Up Washer 16. Aotor Set
4. Washer HiA. Rotor
5. Sua I 1GB. Vane 171
6. lIousing HiC. Stator /
1. Seal fling 121 11. Manifold Plate 23
B. Thrust Washer lB. Manifuld
BA. 1hrust Washer 19. Commutator
9. Thrust BUllring 20. Sual Aillg
10. Bearing 21. Commuta tor Ring
ll. COIlJ.lling Shaft 22. Slueve
lIA. Kuy 23. End Cover Assembly
Special Bolt 111 " /'27
110. Nut 24.
11C. Washer 25. Plug
O·Ring " '.../ 28
Optional Construction
110. Bolt 26.
lock Washer 21. Spring -~ /26
l1E.
12. Bearing 2B. Valve IShunleJ NOTE: "Optional Construction" is for Torqmotors not listed in 0 /25
13. Thrust Bearing charts provided in this manual. ~
CD
----- ....
 HE

NOTE: Assemble Seal Flal Side Oul as Shown in Enlarged

View of Sectioned Segments of lIems Number 19 and 20.

Item
No. Description
t. Seal 14. Drive link
2. Relaining Ring 15. Wear Plaia
3. Oack·Up Washer 16. ROlor Sel
4. Washer 16A. Rotor
fi. Seal 160. Vano 171
6. Iluusing HiC. Sialor
7. Seal Ring 121 17. Manifold Plate
B. Thrust Washer 10. Manifold
BA. Thrust Washer 19. Commulator
9. Thrusl Dearing 20. Seal Ring
10. Oearing 21. Commutator Ring
ll. COllpling Shaft 22. Sleeve
11A. Key 23. End Cover Assembly
l1U. NUl 24. Special Oolt 171
llC. Washer 25. Plug
110. Bolt 26. D·Ring
llE. lock Washer 27. Spring
12. Bearing 2B. Valvo IShulllel NOTE: "Optional Conslruction" is for Torqmolors not listed in
13. Thrust Bearing charts provided in. this manual.
 roubleshooting Checklist
(
I leakage
Cause
1. Hose fittings 100s3, worn or damaged
2. Oil seal rings 171 deteriorated by
excess heat
3. Special bolt 1241 loose or its sealing
area deteriorated by corrosion
4. Internal shah seal 15) worn or
damaged
5. Worn coupling shah /111 and internal
seal 151
;ignificant loss of speed under load 1. Lack of sufficient oil supply
C_
2. High internal motor leakage
3. Severely worn or damaged internal
splines
4. Excessive heat
Low mechanical efficiency or undue 1. line blockage
high pressure required to operate
TorqmotorTW unit
2. In ternal interference
3. Lack of pumping pressure
4. Excessive binding or loading in system
external to MAS/MAE unit.
CAUTION: If the hydraulic system fluid becomes overheated Dn excess of 200 of
:93.3°Cn, seals in the system can shrink, harden or crack, thus losing their sealing
:bility.
(~
~ents
s Gear Division products ·and systems described in this manual are protected by one or more of the following United
.Jtes patents: 3,289,602; 3,288,034; 3,452,680 and 3,606,601. In addition, patent applications have been filed in Brazil,
Canada, Denmark, France, Italy, Japan, Sweden, the United Kingdom, and West Germany.
Remedy
Check & replace damaged fittings
or liD" Rings. Torque to
manufacturers specifications.
••
Replace oil seal rings by
disassembling TorqmotorT~ unit. II>
r
lal Loosen then tighten single bolt to
45-55 h.tbs. 160-76 N m)
Ibl Replace bolt.
1
Replace seal. Disassembly of
TorqmotorT~ unit 'not necessary.
Replace coupling shah and seal by
disassembling TorqmotorT~ unit.
!al Check for faulty relief valve and
adjust or replace as required.
Ibl Check for and repair worn pump.
leI Check for and use correct oil for
temperature 0; operation.
lal Replace worn rotor set by
di~assembling TorqmotorTIoI unit.
Replace rotor set, drive link and
coupling shah by disassembling
TorqmotorTU unit.
••
Locate excessive heat source
lusually a restriction I in the
system and correct the condition.
Locate blockage source and repair
or replace.
Disassemble TorqmotorTY unit,
identify and remedy cause and
repair, replacing parts as
necessary.
Check for and repair worn pump.
Locate source and eliminate cause.
••
 1.185 .
2.370 1.175
.760
2.360
2.260 .740
2.240
2.052 (
2.057

POLISH TO REMOVE SHARP EDGE ONLY

Dimensions Shown in Inche$ Dimensions Shown in Inches

Shaft Shaft
Tool No. Seal Dia. Dim. "A" Dim. "8" Tool No. Seal Dia. Dim. "A" Dim. "S" Dim. "C"
J26751 l1f. 1.25211.258 1.29011.280 J26753 11f. 1.50211.504 1.73511.715 1.5S0/1.61 0
J33074·1 11fz 1.50211.508 1.540/1.530 J33074·3 11fz 1.751/1.753 1.985/l.965 1.840/1.860
Seal Thimble Seal Compression Ring
Figure 1. Figure 3.

4.10
CONVERSIONS
4.00
3.00
3.10
1.240 Inches mm Inches mm
1.260 .740 18.80 1.610 40.89
.760 19.30 1.715 43.55

I 1.175
1.185
1.240
29.85
30.10
31.50
1.735
1.745
1.747
44.07
44.32
44.37
C
'C'DIA
1.252 31.80 1.751 44.48

L 1.258
1.260
1.280
1.290
1.300
31.95
32.00
32.51
32.77
33.02
1.753
1.800
1.840
1.860
2.052
44.53
45.72
46.74
47.24
52.12
1.350 34.29 2.057 52.25
1.498 38.05 2.200 55.88
Dimensions Shown in Inches 1.500 38.10 2.240 56.90
Shaft 1.502 38.15 2.260 57.40
Tool No. Seal Dia. Dim. "A" Dim. "B" Dim. "c" 1.504 38.20 2.360 59.94
J26752 11/. 1.30011.350 1.50011.498 1.80011.600 1.508 38.30 2.370 60.W
J33074-2 lVz 1.550/1.600 1. 74 711. 745 2.40012.200 1.530 38.87 2.400 60.96
1.540 39.12 3.00 76.2
Seal Driver 1.550 39.37 3.10 78.7
Figure 2. 1.590 40.39 4.00 101.6
1.600 40.46 4.10 104.1

NOTE: Tool Kit J26905 for 1~ inch (32 mm) seal diameter coupling shaft includes
tools J26751, J26752 and J26753.
Tool Kit J33074 for 1Yz inch (38 mm) seal diameter coupling shaft includes
tools J33074-1, J33074·2 and J33074-3.
Tool Kits available from: Kent·Moore, 29784 little Mack, Roseville, Michigan
46066, Phone (313) 774·9500.
(
2

.
 !~
n ~ \

MAB :lervice Parts List Chart (1 %Inch, 31.8 mm, ",eal Dia. Coupling Shaft)
U)

CIIART USE EXAMPLE: MAB06002 TOROMOTOR'M INCLUDES PART NUMBERS lISTEO TO THE RIGHT OF MAB, 06· ANO ·002 SHOWN IN lEFT HAND COLUMN
OF CHART.
CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS fOR THE TOROMOTORS LISTED ONLY. REFER TO TIfE ORIGINAL EOUIPMENT MANUFACTURER
OF TlfE EQUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BelOW.
EXPLODED VIEW
ITEM I ,. 2" 30
40
So 7 0

DESCIlIPIION Seal netaining ning Back·Up Washer Washer Seal Seal ningl21
MAB SEnVICEPAIIT I 032436 40'1346 028398 029106 032633 032519
EXPLODED VIEW
ITEM I 8 & 8A o• 90
• 10 0
• 12·· 13 0
• 15
DESCRIPTION Thrust Washcrl21 Thrust Dearing Dearing Bearing Thrust Dear iug Wear Plato
MAB SERVICE PART I 4oiHo3 067029 070502 010501 067031 477237
EXPLODED VIEW
IHMI 17 + 18 19 t 21 2O· 23
O£SCRIPTION Manifold Plate .. Manifold Commutator Assy. Seal ning End Cover Assy.
MAB SERVICE PAnT I MAB015003X1 MAB018000S1 032435 MABO 1GOOOA 1
EXPLODED VIEW
ITEM' 14 16 22 24
DESCRIPTION Drive Link notor Set Sleeve Special Boll 171
06· SERVICE PART I MAB083001 MAD067001A 1 099025 021270
08· SERVICE PART I MAD083001 MAB087000A2 099025 021270
10· SERVICE PART , MAB103000 ,MAB 107000A 1 099091 021270
16· SERVICE PAnT I MAB 163001 MAB 167000A2 099026 021271
24· SERVICE PAnT I MAB243001 MAB247000A3 099024 021272
32· SERVICE PART I MAB323001 MAB327005A 1 099085 021273
EXPLODED VIEW
ITEM~ 6 11 11A llB·· • 11C 110 l1E
DESCRIPTION Ilousing Coupling Shah Key Nut Washer Bolt Lock Washer
·002 SERVICE PAnT I MAB012000A 1 091399
·003 SERVICE PART I MAB012002A 1 091404 039027 025126
·004 SERVICE PART , MAB012000A 1 091404 039027 025126
·005 SERVICE PART I MABO 12002A 1 091399
·008 SERVICE PART I MAB012000A 1 091405
·009 SERVICE PAnT , MABO 12002A 1 091405
·010 SEnVICE PAnT I MAB012000Al 091416 039028 028413 G223734 Gl03325
·011 SERVICE PART , MABO 12002A 1 091416 039028 028413 G223734 Gl03325
·014 SERVICE PART , MAB012002A 1 091462 028413 G223734 Gl03325
·015 SERVICE PART I MAB012000A 1 091937
·016 SERVICE PART I MAB012000Al 091462 028413 G223734 G103325
·017 SERVICE PART I MAB012002A 1 091437
·041 SERVICE PART I MAB012000A 1 091435
NOTES:
-Included in MAB500003-standard seal kit. Other kits: MAB500004-viton, synthetic lIuid applications. MAB500005-cold lemperalUre applications.
··Included with item 16, Service Ilousing Assembly•
• " "Item 111 B nut service pan numbor listed is lor Torqmotor assembly part numbers with an A1 suffix only.
hem 1110 nut service palt number lor Torqmotor assembly part numbers with an A4 sullix is 025113.
Itel\l 1110 nul servico pall number lor TOlqmotor assembly part numbers wilh an A7 sullix is 025132.

C 0 0
. -._-_.-_.- J ••
,~--~
I
~
~
~~1'1;
I:
MAE (Standard) Service Parts List Chart (1 %Inch,
CIIART USE EXAMPLE: MAE·10002 TOROMOTOR
OF CHART.
rM
~ 1.8 mm, Seal Dia. Coupling Shaft)
INCLUDES PART NUMBERS LISTED TO THE RIGIIT OF MAE, 10· AND ·002 SIIOWN IN LEFT HAND COLUMN

CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EOIJIPMENT MANUFACTURER
OF THE EOUIPMENT USING HIE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW.
}
EXPLOOEO VIEW
ITEM / 1· 2· 3· 4· 5· 7·
DESCRIPTION Seal Retaining Ring Back·Up Washer Washer Seal Seal Ringl21
MAE SERVICE PART I 032436 401393 028398 029106 032633 032519
EXPLODED VIEW
ITEM / B & BA·· 9·· 10·· 12·· 13·· 19+21 20· , ......
DESCRIPTION Thrust Washerl21 Thrust Bearing Deari!!g [learing Thrust Bearing Commutator Assy. See I Ring
MAE S[RVICE PART I 400103 067029 070502 070501 067031 MAB018000S1 032435
~

EXPLODEQ VIEW
ITEM/ 14 15 16 17 16 22 23 24
DESCRIPTION O,ive Link Wear Plate Rotor Set Manilold Plate Milniluld Sleeve End Cover Assy. Special BolIl7I
, 099082
10· SERVICE PART / MAE103000 477259 MAE107000 477260 MAE015000 MAE016000Al 021271
14· SERVICE PART / MAE143000 477259 MAE147000 477260 MAE015000 099096 MAEO 16000A 1 021352
20· SERVICE PART / MAE203000 477259 MAE207000 477260 MAEOl5000 099092 MAE016000A 1 021340
24· SERVICE PART / MAE243000 477259 MAE247000 477260 MAE015000 099066 MAEO 16000A 1 021273
34· SERVICE PART / MAE343000 477257 MAE347000 477256 MAB015003 099064 MABO 16000A 1 021273
68· SERVICE PART / MAE683000 477257 MAE687000 477256 MAB015003 099079 MAB016000A 1 021329
£XPLOD£O VIEW
ITEM"", 6 11 11A 110·· • l1C 110 l1E
OESCRIPTION Housing· Coupling Shah Koy Nut Washor Doh lock Wesher
·002 SERVICE PART I MAB012000Al 091443
·003 SERVICE PART I MAB012002A 1 091442 039027 025126
·004 SERVICE PART / MABO 12000A 1 091442 039027 025126
·005 SERVICE PART / MAB012002A 1 091443
·008 SERVICE PART I MABO 120aOA 1 091445
·009 SERVICE PART / MABO 12002A 1 091445
·010 SERVICE PART I MAB012000A 1 091441 039028 028413 G223734 Gl03325
·011 SERVICE PART / MAB012002A 1 091441 039028 028413 G223734 Gl03325
·014 SERVICE PART / MAB012002A 1 091453 028413 G223734 Gl03325
·015 SERVICE PART / MAB012000A 1 091452
·016 SERVICE PART / MAB012000A 1 091453 . 028413 G223734 Gl03325
·017 SERVICE PART / MAB012002A 1 091452
·029 SERVICE PART / MABO 12007Ar·· • 091460 039027 025126

-~-.,

N.OTES:
·Included in MAB500003-standard soal kit. Other kits: MAB500004-viton, synthetic lIuid applicetions; MAB500005-cold tomperatura applications.
• ·'ncluded with item 16, Service lIousing Assembly.
···hem 111B nut service part number listed is for TorqmolOr assambly part numbers with an Al sullix only.
hom /l1B nut service part number for Torqmotor assembly part number with an A4 sullix is 025113.
Item /11B nut servica part number for Torqmotor assambly part number with an A7 sullix is 025132•
••• ·tlousing MABO 12007A2 uses chemfered washer 1400135 for item 8A in the exploded essembly view.

I~
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.
~
~

':..I l
r

~- .. -
.
""lcrVICO Parts List Chart (1 ~ Inch, 38.1 nllla, Sell Dia. Coupling Shaft)
CHART USE EXAMPLE: MAE10037 TOROMOTOR'" INCLUOES PART NUMBERS lISTEO TO THE RIGHT OF MAE, "J. and ·037 SHOWN IN LEFT HAND COLUMN OF
CHART.
CAUTION: TilE CIIARTED COMPONENT SERVICE INFOnMA TlON IS FOR TilE TOROMOTORS LISTED ONLY. REFER "0 T"E ORIGINAL fOUIPMENT MANUFACTURER
OF TilE EQUIPMENT USING TilE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BElOW.

EXPLODED VIEW
ITEM I 1· 2· 3· 4" 5' r
DESCRIPTION Seal Relaining Ring Back,Up Washer We: her Shah Seal Seal Ring 121
MAE SERVICE PART I 032752 401431 02B475 Oi.l1 07 032726 D~2519
EXPLODED VIEW
ITEM I 0" BA·· g" 10; 12" 13"· 19 +21 20·
DESCRIPTION Thrust Washer Thrust Washer Thrust Dearing Dealingl21 Thrust nearing Commulator Assy. Sea! fling
MAE SERVICE PART I 400136 400138 069017 07ln17 068024 MABOl~onos-t O~j 115
EXPLODED VIEW
ITEM I 14 15 16 17 18 22 23 24
DESCRIPTION Drivo Link Wear Plate Rotor Set Man :old Plate Manifold Sleeve End Lover Assy. Special sollm
10· SERVICE PART I MAEI03000 477259 MAEI07000 477760 MAE015000 099082 MAW 16000A 1 0212~
14· SERVICE PART I MAE143000 477259 MAE147000 47: GO MAE015DOO 099096 MAE016000A 1 021352
20· SERVICE PART I MAE203000 477259 MAE207000 477~ 60 MAE015000 099092 MAEOI6000A 1 021340
24· SERVICE PART I MAE243000 477259 MAE247000 477260 MAE015000 099066 MAE016000A I' 021273
34· SERVICE PAnT I MAE343000 477257 MAE347000 47/;6 MAB015003 099064 MABO I 6000A 1 021273
68· SERVICE PART I MAE683000 477256 MAE687000 477;;56 MAB015003 099079 MABOI6000A 1 021329 iff
EXPLODED VIEW
ITEM I 6 11 I1A 0'-.
11 B For Al Assys. 110··· For M Assys. 1lB··· For A7 As~.

DESCRIPTION lIousing Coupling Shah Key Nut Nut Nut

·OJ7 SERVICE PART I MAB012015A 1 091468 039039 025" '11
·038 S£AVICE PART I MAB012013Al 091466 039027 0251'6 025113 025132
·039 SERVICE PART I MAB012014Al 0914.66 039027 025L!6 025113
MAB012014Al 091468 039039 0251'11 025133
·040
·048
SERVICE PAnT I
SERVICE PART I MAB012015Al 091466 039027 0251'6 025113 . , -.
J - ...,~ ~
"'h'

NOTES:
'Included in MAE500003-Slandard seal kit.
• •Included with itom 16, Survico lIuusing Assombly •
•• 'hern 1110 nut sO/vico part /lumber varios 8S shown lor rurQlllolor assembly parI numbers listed that have an AI, A4 or A7 suffix.

o
---....--

Otisass'e'mbly "and "Inspection Piocedures
PREPARATION BEFORE DISASSEMBLY
Before disconnecting hoses, thoroughly clean off all outside dirt
around fittings. IAfter disconnecting hoses and before removing
from vehicle, IMMEDIATELY plug portholes.1 Orain fluid and
finish cleaning and drying assembly before placing on a clean
work surface. IA piece of clean paper makes an excellent
disposable top.) All disassembled parts should be cleaned
separately in clean petroleum-based solvent and blown dry
with air to avoid nicks and burrs. Discard all seal and seal
rings as they are removed from Torqmotor. Use Ross Gear
Division or OEM approved service parts.
WARNING: SINCE THEY ARE FLAMMABLE, BE
EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN
A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR
DEATH.
WARNING: WEAR EYE PROTECTION AND BE SURE TO
COMPLY WITH OSHA OR OTHER MAXIMUM AIR·
PRESSURE REQUIREMENTS.
CAUTION: Never steam or high pressure wash hydraulic
components. Do not force or abuse closely fitted parts.
REPLACEMENT OF HIGH PRESSURE SEAL (5) WITHOUT
COMPLETE TDRQMOTOFrM DISASSEMBLY
!Reference Exploded Assembly View)
i. Remove and discard dirt seal 111and retaining ring 12)
from Torqmotor. [Some applications may not require dirt
seal (1).1
2. Completely fill Torqmotor with oil. Plug "A" and "8"
ports and set Torqmotor in a clean pan. Place a clean
rag around the coupling shaft seal area of the housing
to prevent oil spray. Carefully grip coupling shaft with
appropriate wrench and rotate coupling shaft rapidly in a
counter-clockwise direction. Oil pressure generated by
Torqmotor will eject backup washer 131, washer 14\ and
seal 151.
3. Select the proper seal assembly tools for the 1V. inch
131.8 mml or 1Y2 inch (38.1 mm) seal diameter coupling
shaft involved. See Figures 1, 2 and 3, page 2. '
Insert the selected seal compression ring tool IFigure 3\,
with chamfered end inward, into housing 161 until it
bottoms out. Assemble the selected seal thimble tool
IFigure 11 over coupling shaft 1111. Coat new seal 151
with clean grease and assemble over seal thimble with
lip side inward. Push new seal 151 into housing (6) with
the appropriate seal driver tool IFigure 21. Remove seal
driver, thimble and compression tools.
4. Hold washer 141 between thumb and index finger and
slightly collapse washer and assemble into housing 161.
Assemble back-up washer 131 tab side out, and retaining
ring 121. Be sure rounded edge of retaining ring is faced
inward, and that back-up washer tab is between ends of
retaining ring. Be sure the new retaining ring 121 is the
same thicknes~ as t.h~ qn~ ~~~qved. ISeal kit contains
c
lr'"i.· . ,. ,. . . .,.
!'NOretaining rings to select from.1 Apply a small
amount of clean ·grease to the back side of new seal III
and assemble into housing 161 if required.
( . '\
i
TORQMOTOR DISASSEMBLY
IReference Exploded Assembly View)
1. Place Torqmotor in a vise, clamping down on the
housing 161 port bosses with the coupling shah 1111
pointed down.
WARNING: IF THE TORQMOTOR IS NOT FIRMLY HELD IN
THE VISE, IT COULD BE DISLODGED DURING THE
SERVICE PROCEDURES, CAUSING INJURY.
2. If the end cover assembly 123) has a valve 128), scribe a
line on housing 161 in some manner in line with the port
in the end cover for reassembly orientation. Loosen the
two plugs 125) with a 3/16 inch Allen wrench, for later
disassembly. Remove the seven special bolts 1241 using a
9/16 inch thin wall socket. Inspect bolts for damaged
threads, or the sealing ring under the bolt head. Replace
damaged bolts.
3. Remove end cover assembly 1231 and seal ring 171 by
inserting screwdriver between end cover assembly and
sleeve 1221. Pry up end cover assembly and lift from
U;;!l \vith seal ring enached. r;~·:2:d ~23! ring !71. It may
be necessary to use a chisel and hammer to break the
end cover loose.
4. If the end cover 123) has valve (28) and the previously
loosened plugs 1251, remove the two plugs and O-rings
1261.
CAUTION: Be ready to catch two springs (27) and
valve (28) that will fall out of the end cover valve
cavity when the plug assemblies are removed.
Thoroughly wash cover in proper solvent and blow dry.
Be sure the cover valve apertures, including the internal
orifice plug, are free of contamination. Inspect end cover
for cracks and the bolt head recesses for good bolt head
sealing surfaces. Replace cover as necessary.
NOTE: D·ring (26) is not included in seal kits but is
serviced separately if required.
5. Remove commutator ring 1211, commutator 1191, seal
ring 1201, and manifold 1181 by using two of the special
bolts 1241 as a lifting tool-insert the two special bolts
into two holes and lift out the previously mentioned
parts.
6. Remove seal ring 120\ from commutator 1191, using an
air hose to blow air into ring groove until seal ring is
lifted out and discard seal ring. Inspect commutator and
commutator ring 121\ for cracks or burrs. Inspect
commutator for wear, scoring, spalling or brineHing. If
any of these conditions exist, replace commutator and
commutator ring as a matched set. ()
7. Remove manifold plate 1171 by again using twO special
6
 bolts (241 as a lifting tool. Inspect manifold (181 and -
manifold plate (171 for cracks, surface scoring, brinelling'
or spalling. Replace manifold or manifold plate that
exhibits any of these conditions. A polished pattern on
e- the ground surfaces from commutator or rotor rotation
is normal.
8, Remove r6to r set (161 and wear plate 1151, by again
using the two bolts as a lifting tool. Retain rotor set in
its assembled form, if possible, to maintain the same
rotor vane to stator contact surfaces. Inspect the rotor
set in its assembled form for nicks, scoring, or spalling,
on any surface and broken or worn rotor splines. If any
rotor set component requires replacement, the complete
rotor set must be replaced as it is a matched set.
Inspect the wear plate for cracks, brinelling, or scoring.
9. Place rotor set on a flat surface and center rotor 116AI
in stator 116Cl such that two rotor lobes 1180 0 apartl
and a roller vane 11681 centerline are on the same
stator centerline. Check the rotor lobe to roller vane
clearance vyith a feeler gage at this common centerline.
If there is more than .005 inches 10.13 mml of
clearance" replace rotor set.
1O. Remove drive link 114) from coupling shah Ill) if it was
not removed with rotor set and wear piate. Inspect
drivelink for cracks and for worn or damaged splines. No
perceptible lash Iplayl should be noted between mating
~~ .. :,~ PCi",
Remove thrust bearing (13) and inspect for wear,
brinelling, corrosion, and a full complement of retained
C 12.
rollers.
Remove coupling shaft 1111 by pushing on the output
end of shah. Inspect coupling shaft bearing and seal
surfaces for spalling, nicks, grooves, severe wear or
corrosion and discoloration. Inspect for damaged or worn
internal and 2xternal splines or keyway. Replace coupling
shaft if any of these conditions exist.
NOTE: Minor shaft wear in seal area is permissible.
If wear exceeds .020 inches (0.51 mm) diametrically,'
replace coupling shaft.
A slight "polish" is permissible in the shah bearing area.
Anything more would require coupling shaft replacement.
13. Remove sleeve 1221 by inserting screwdriver between
sleeve and housing 161 and pry up. Inspect sleeve for
deformation from the original cylindrical shape to a
"barrel" or "hour glass" shape, Inspect sleeve ends for
severe nicks, burrs or corrosion. Replace sleeve if any of
these conditions exist.
NOTE: Minor burrs and corrision that would damage
new seal rings during assembly can be removed from
sleeve ends.
L Remove seal ring 171 from housing (6) and discard seal
( ring.
Remove housing 161 from vise; turn over and reclamp in
15.
vise with dirt seal 111 end pointed up.
7
16.' Remove dirt 'seal (11, retaining ring (21, back-up washer
131, washer 141, and seal 151 from housing (61. Discard
seals and washers but keep retaining ring (21 for
comparison when selecting new retaining ring from seal'
kit. If burr exists on retaining ring groove, remove with
a scraping tool.
'J
17. Inspect housing 161 assembly for cracks, the machined
surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimensional
characteristics. Inspect tapped holes for thread damage.
If the housing is defective in these areas, discard the
housing assembly and the disassembly of the Torqmotor
is complete.
18. If the housing assembly 161 has passed inspection to this
point, inspect the bearings 191, 110)' 1121 and thrust
washers 181 and 18AI. The bearing rollers must be firmly
retained in the bearing cages, but must rotate and orbit
freely, All rollers and the thrus\ washers must be free of
brinelling and corrosion. If the housing has passed this
inspection the disassembly of the Torqmotor is
completed.
19. If only the outer bearing 1121 requires replacement,
carefully use a suitable bearing puller to remove bearing
so the housing is not damaged.
If bearing 1101 requires replacement, use a 1.48S inch
20.
137.80mm) maximum diameter shaft or a 1.745 inch
\. ': ~,.22 i' : --·~<:;T.L::T ;:::;:n:;:9' ;~?~ 1-?7:l~ en the
internal seal (5) bore diameter and press out thrust
washers 181, ISAI, thrust bearing 191, and bearings 1101
ana 112l. The housing wearpl2te face should be placed
on a block of wood during the pressing operation to
::)
protect it. Discard thrust washers lSI and ISAI, thrust
bearings 191, and bearings (101 and 1121 and replace
with new parts, as parts will have been damaged when
being pressed out.
NOTE: The depth or location of bearings (10) and
(12) in relation to the housing wearplate face should
be measured and noted before pressing the bearings
out. This will facilitate the correct reassembly of
new bearings.
The disassembly of Torqmotor is completed.
:.J
TOROMOTOR ASSEMBLY PROCEDURES
(Reference Exploded Assembly View)
Replace all seals and seal rings with new ones each time you
reassemble the Torqmotor unit. lubricate all seals and seal
rings with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a
complete seal kit are available. The parts should be
available through most OEM parts distributors or Ross
approved Torqmotor distributors. (Contact your local dealer
for availability.)
NOTE: Unless otherwise indicated, do not oil or grease
parts before assembly.
Wash all parts in clean petroleum·based solvents before
assembly. Blow them dry with compressed air. Remove
any paint chips from mating surfaces of the end cover,
sleeve, and housing and from port and sealing areas.
HOUSING BEARING REPLACEMENT PROCEDURES
1. If bearing components were removed for replacement,
assemble new thrust washer 181, new thrust bearing 191
and new thrust washer ISA) in that order into housing
16) bearing cavity. If thrust washer ISA) has a chamfer
on the inside diameter, the chamfered side must face
away from thrust bearing (91.
NOTE: Thrust washer (SA) will be identical to thrust
washer (8) unless a chamfered inside diameter is
required because of coupling shaft design.
NOTE: An appropriate size piloted bearing mandrel is
required to press in housing bearings.
2. If bearings 1101 and 1121 required are for a 2.25 inch
157.2 mm) diameter Inominal) housing bearing bore,
press in new bearing \101 which is 1.0 inch 125.4 mm)
long, into housing 161 bearing bore to a depth of 2.410
± .010 inch 161.2 ± 0.254 mml, measured from the
housing wear plate contact surface. Then, press in new
bearing 1121 which is .5 inch 112.7 mm) long into
housing bearing bore to a depth of .115 ± .010 inch
12.92 ± 0.254 mm} measured from the housing wear
plate contact surface.
NOTE: Press against the lettered end of bearing cage
when pressing in a roller bearing assembly.
3. If the bearings (10) and (12) required are for a 2.50
inch 163.5 mm) diameter Inominall bearing bore, press in
new bearing 1101 which is 1.0 inch 125.4 mm} long into
housing 16) bearing bore to a depth of 2.379 ± .010
inch 160.43 ± 0.254 mml measured from housing wear
plate contact surface. Press new bearing 1121 which is
identical to bearing 1101 into housing bearing bore to a
depth of .115 ± .010 inch 12.92 ± 0.254 mml
measured from the housing wear plate surface.
NOTE: The bearings (10) and (12) must be assembled
to the correct depths to assure the necessary .
clearance for thrust washer (8AI and thrust bearing
(13) and to assure required bearing support.
TOROMOTOR
,. ASSEMBLY
If the seaung diameter of the coupling shaft 1111 is larger than
any other diameter on' the ootput end of the coupling shah,
begin the Torqmotor assembly procedures with Step 1 below.
If there is a diameter on the output end of the coupling shah (l
equal to the sealing diameter or the coupling shaft begin the
procedures with Step 6 below.
1. Place housing .161 in a vise and clamp down on housing
pon bosses with small bore end pointed up. Apply clean
grease to new seal 15) and assemble into housing with
seal lip pointed inward.
2. Hold washer 141 between thumb and index finger and
slightly collapse to facilitate assembly into housing 161.
3. Assemble back-up washer (3) into housing 161 with the
anti~rotation tab facing out.
4. Select a new retaining ring 121 from the seal kit, that is
the same thickness as the retaining ring removed.
Assemble the new retaining ring into housing 161. Be
sure rounded edge of retaining ring is faced inward and
that back-up washer tab is between ends of retaining
ring.
5. Apply a small amount of clean grease to back side of
new seal 111 and assemble into housing 16), if a seal 11)
is required.
6. Invert housing 16) in vise so that the large bore end is
up.
7. Apply cellophane tape around splines or keyway on
coupling shah 1111·to prevent damaging seals.
C~
8. Assemble coupling shah Ill), firmly seating it against
thrust washer (8AI.
9. Assemble thrust bearing 1131 onto end of coupling shah
1111.
10. Assemble drive link Ii 41 into coupling shah 1111 with
their splines in mesh. !Align hole in drive link with hole
in coupling shah 1111, if applicable.)
NOTE: Two alignment studs screwed finger tight into
housing (6) bolt holes, approximately 180 0 apart, will
facilitate the assembly and alignment of components as
required in the following procedures. The studs can be
made by cutting off the heads of 3/8·24 UNF 2A bolts
that are over .5 inch (12.7 mm) longer than the bolts (24)
used in the Torqmotor.
11. Assemble wear plate 1151 over drive link 1141 and studs
onto housing 161.
12. Install assembled rotor set (16) with counterbore in rotor
116A1 down, if applicable, and splines in mesh with drive
link splines.
NOTE: If necessary, go to "Rotor, Stator, Vane
Assembly" procedures on page 9.
13. Assemble manifold plate (17), manifold (181 and then the
commutator ring 121) over the drive link t141 onto rotor
set 116) per the exploded assembly view. Be sure swirls
in manifold and manifold plate are faced together.
8
,\,,;~ir:;';i'~'~:;'~efu'Ole a~:ne\V 'Seal"(H1ff'\iuJ'~'n,n:~i-i!~{\jj'p, jjILU.

commutator (191 and assemble commutator over end of

drive link 114) onto manifold 118) with seal sideup.
15. Assemble new seal 171 on housing 161, apply a generous
amount of SAE 10W40 to both ends of sleeve 1221 and
assemble onto housing. Make sure sleeve is sitting in a
( Torqmotor assembly procedures 1 through 11.
non·cocked position.
16. Turn a plug 1251 with a new D-ring 1261 if required
loosely onto one end of cover 1231 valve cavity if
required.
17. Then insert a spring (21l, tne valve 1261 and anuu'18r
spring 1271 into the other end of the valve cavity. Turn
another plug 1251 with new D-ring 1261 loosely into
cover valve cavity.
18. Assemble a new seal ring 171 onto end cover and
assemble end cover onto sleeve 1221 in a non-cocked
position.
NOTE: If the end cover has a valve (281 use the line
you previously scribed on the housing (6) to radially
align the end cover port into its original position.
19. Assemble seven special bolts 1241 and screw in finger
tight. Removal of the two alignment studs should be
made after at least two bolts have been assembled.
Alternately and progressively tighten the bolts to pull
end cover assembly 1231 and sleeve 1221 into place with
a final torque of 50 :!:: 5 h.lbs. 168 :: B N ml.
Tightening sequence:
A disassembled rotor 116AI, stator 116C} and vanes (1681 that
cannot be readi,ly assembled by hand can be assembled by the
following procedures. . .
1. Place stator (16CI onto wear plate 1151 after following
2. If assembly al\gnment studs are not being utilized, align
stator bolt holes with wear plate bolt holes and turn
two. bolts 1241 finger tight into bolt holes 180 0 apart to
retain stator and wear plate stationary.
3. Assemble six vanes 11681 into the stator vane pockets.
4. ~semble rotor 116M, counterbore down, if applicable,
Into stator 116CI and onto wear plate l151 with rotor
splines in mesh with drive link splines.
5. G~asp the output end ~f coupli~g shaft 1111 with locking
pliers or other approprtate turning devices and rotate
coupling shaft, drive link and rotor to seat the rotor and
assembled vanes into stator, creating necessary clearance
to assemble seventh vane. Assemble the seven vanes
using minimum force.
6. Remove the two assembled bolts if used to retain stator
and wear plate.

0 6 1 3

c 2 7
5

NOTE: The special bolt (24) required for use with the
shuttle valve (28) end cover assembly (23) is longer
than the bolt required with the standard end cover
assembly. Refer to the individual service parts list
for correct service part number.
20. Torque the two plug assemblies 1251 in end cover
assembly to 12-19 ft.lbs. 116-26 N ml.
21. If seal 151, washer 141, back-up washer 131, snap ring (21
and seal 111 have not yet been assembled, invert housing
in vise so the coupling shah 1111 is pointing up and
follow procedures #3 and #4 under "Replacement of
High Pressure Seal" on page 6 to assemble these
components.
The assembly of Torqmotor is now complete except for
woodruff key 111 AI, nut 11181, washer 111 CI, bolt 111 01 or
lock washer (11 EI if applicable at Torqmotor installation. See
final checks.

c,
9
J

• Pressurize the Torqmotor W with 100 p.s.i. 16.9 BARI dry nitrogen and ~ubmerge in
solvent to check for external leaks.
• Check TorqmotorW for rotation. Torque required to rotate coupling shaft should not be
more than 50 h.lbs. (68 N ml
• Pressure port with "A" cast under it on housing 1181 is for counter-clockwise coupling
shaft rotation as viewed from the output end of coupling shaft. Pressure port with "8"
cast under it is for clockwise coupling shaft rotation.
• Use test stand if available, to check operation of the TorqmotorTLI •

Hydraulic Fluid
Keep the hydraulic system filled with one of the following:
• 10W40 SE or SF manufacturers suggested oil.
• Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not
drop below 50 SSU or contain less than .125% zinc anti-wear additives.
CAUTION: Do not mix oil types. Any mixture, or an unapproved oil, could
deteriorate the seals; Maintain the proper fluid level in the reservoir. When (
changing fluid, completely drain old oil from the system. It is suggested also that
you flush the system with clean oil.

Filtratio n·
Recommended filtration 20-50 micron.

Oil Temperature
Maximum operating temperature 200 OF 193.3°el.

10
 -Tips for Maintaining the Torqmotor"'
Hydraulic System

• Adjust fluid level in reservoir as necessary.

• Encourage all operators to report any malfunction or accident that may have damaged
the hydraulic system or component:
• Do not attempt to weld any broken Torqmotorll component. Replace the component
with original equipment only.
• Do not cold straighten, hot straighten, or bend any TorqmotorTIl part.
• Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area
around and the filler caps before checking oil level.
• Investigate and correct any external leak in the hydraulic system, no matter how minor
the leak.
• Comply with manufacturer's specifications for cleaning or replacing the filter.
CAUTION: 00 not weld, braze, solder or any way alter any Torqmotor™ component.
CAUTION; Maximum operating pressure must not exceed recommended TorqmotorTloC
pressure capacity.

c CAUTION: Always carefully inspect any system component that may have been struck
or damaged during operation or in an accident. Replace any component that is
damaged or that is questionable.
::)
CAUTION: 00 not force any coupling onto the TorqmotorTIII coupling shaft as this could
damage the unit internally.
Ross Gear extends close technical cooperation and assistance. If problems occur which you
cannot solve, please contact our Ross Service Department or local Ross approved Distributor.
Our phone number and telex number and address are on the back cover of this manual.

( J
"\

11
 . , ......
~.
_.:.. .-
·"

VlAB and MAE =Series Service Procedure

'.,

...~.-.
fl'WW."
Write or call for information and added details
concerning your installation and applications;
Phone: 317.423.5377
Telex: 279413
Write: Ross Gear Division
"aoo Heath Street
Lafayene, Indiana 47902
 (I)
(1)
-:,..
r-:~

(J)
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co
T-
( )
 INTRODUCTION

The purpose of this manual is to prOyj0c the information necessary for the
servicing of the Sundstrand-Sauer 18 Series hydrostatic transmissions.
This includes general description, circuit development, trouble shooting,
tI disassembly and repair. The repair procedures are divided into Minor and
Major repairs covering the fixed and variable displacement r;;ctors as well
.i as the variable displacement pumps.

Minor repairs are those that can be performed without removal of the end
cap and can be accomplished without effecting the unit warranty,

Major repairs are those requiring the removal of the end cap. Major repairs
may effect the unit warranty; therefore, the equipment manufacturer
should be consulted prior to undertaking such repairs.

C. C·
Sundstrand-Sauer provides a complete repair service for its products.
I --_._'
Contact any Sundstrand-Sauer Authorized Service Centc~~ f,)r dc:tails_

'.j

I
.. '.1I

:-r
.:;;~
,-,. i
<}
':~
. - ~,

- ...
C .'
,

.-......
 · ~'.

TABLE OF CONTENTS

Section Description Page

Introduction

Section 1: . Configuration and Specitications 1-3

Section II: -: _._- System Circuit Description·· -. 4-8
Section III: Fluid Recommendations 9
Section IV: Start Up Procedure 10
Section V: System Maintenance 11
Section VI: Trouble Shooting Procedures 12-15
Section VII: Minor Repair Procedures 16-23
Section VIII: Major Repair Procedures 24-48
Fixed Displacement Motor 24-30
Variable Displacement Pump 31-40
Variable Displacement Motor .~. 41-48
Section IX General Parts Identification ·49-53
Fixed Displacement Motor 49
Variable Displacement Pump 50-51
Variable Displacement Motor 52-53
Tandem Pump Service Data 54-60

Copyright, 1974, 1987, Sundstrand·Sauer. All rights reserved.

The contents of this bulletin are subject to change without
notice or obligation. Printed in U.SA 1287 S
 SECTION I: CONFIGURATION AND SPECIFICATIONS

PUMP
VARIABLE DISPLACEMENT MOTOR
VARIABLE DISPLACEMENT

MOTOR
FIXED DISPLACEMENT

SPECI FICATIONS

PUMP DISPLACEMENT: 0-2.3 IN3/REV.

PUMP INPUT SPEED: UP TO 3900 RPM
MOTOR DISPLACEMENT: 2.3 in3/REV
MOTOR OUTPUT SPEED: 0-3900 RPM . - 00-

MAX. OPERATING PRESSURE: 3500 PSI

CHARGE RELIEF SETIING: 100 PSI MIN. @ 1800 RPM
MAX. CONTINUOUS INLET VACUUM: 51N. HG.
MAX. CASE PRESSURE: 25 PSI
. INLET FILTRATION: 25 MICRON (NOMINAL)
CHARGE PUMP DISPLACEMENT: OPTIONAL AT:
.5,.7 OR 1.04 IN3/REV.

CONSULT MODEL NUMBER OF UNIT TO DETERMINE SPECIFIC UNIT CONFIGURATIO~

REGARDING THESE OPTIONAL ITEMS:

SHAFT TYPE
..\.
CHARGE PUMP DISPLACEMENT
AUXILIARY PUMP MOUNTING PAD
BY PASS VALVE

. ;
 SECTION I:
•.::, ,
CONFIGURATION
..... ,.
AND
c· ';'..
~"".r,
SPECIFICATIONS
... '
'! . ,,_ ' .... , . ~ 0-.-0:,. '. ,.: :.... ' .... ,., ,0: -.:,_- ,

,.' -,.\

DRAIN PORT
INLET PORT TOP & BOTTOM
1 5/1 ~1 2 SAE O-RING TYPE 3/4--16 SAE
o-RING TYPE
.. : .... DRAIN PORT
TOP & BOTTOM
" 0
3/4--16 SAE
O-RING TYPE
"."

CHARGE:
PRESSURE
GAUGE PORT-
BOTH SIDES
7/'~20SAE
O·RING TYPE

MAIN PORT - BOTH SIDES

1 5/'~12 SAE O-RING TYPE
GAUGE PORTS (2) INPUT SHAFT
SYSTEM PRESSUR E CONTROL SHAFT
1/8 PIPE TtiREAD
BOTH SIDES"" 0 "_'

(
... '::

MOUNTING FLANGES FOR BOTH PUMP AND MOTORS ARE SAE TYPE B 2 BOLT

MAIN PORT·BOTH SIDES

1-5/1 ~12 SAE DRAIN PORT
O-RING TYPE TOP & BOTTOM
3/4-16 SAE
O-RING TYPE

.00 : '"

." ...,.-- .'. '0·-:--.

--': ~-' :~ ,~

.....
:

.....:
'::: .'.
00

" 0"

CONTROL SHAFT
I
) BOTH SIDES
(
---)"

I .' •• .~.
 :};;;l";~~~"~;.;7··;'·:":':-::'::~
SECTION I: CONFIG'URATION AND SPECIFICATIONS

( :-
\..::..

DO NOT u·se·impact force when· installing I nstalling collars, yokes, couplings, etc., ~n th is
control linkage. Driving axially on the control manner can cause seal leakage and shearing of
shaft will result 1ninternal damage to the pump: swashplate drive pir.s.

AUXILIARY PUMP MOUNTING PADS

MOUNTING PADS SHOWN

WITH COVER PLATE

·1

r,-'.

/ \..i~
SAETYPE A SAE TYPE AA
( 2 BOLT 2 OR 4 BOLT

·~l _ ._. .. ........ .

.' .........
~ .~~::::>.; ~ :.: :. . ..... ..
~
 SECTION II: SYSTEM CIRCUIT DESCRIPTI9N

Pump/Motor

The 18 Series hydrostatic transmission consists

FLOW 81-0IRECTIONAL
of a variable displacement axial piston pump
connected in a closed 'Ioop to a fixed
displacement axial piston motor. The variable
displacement pump is driven by a prime mover
----
(internal combustion engine, electric motor,
etc.) and the fixed displacement motor, which is
driven by the fluid from the pump, drives the
machine {vehicle, hoist, conveyor, etc.} The
direction of rotation and speed of the fixed
motor output shah depends on the flow from
MANUAL OUTPUT SHAFT
the pump. The system pressure is determined by CONTROL 81-DI~EC710NAL
the machine load.

Charge Pump

The axial piston pump and motor have a small

amount of internal leakage which is removed
from the Pump/Motor closed loop circuit. This CHARGE RELIEF .' CHARGE
CHECK
results i.n fluid loss from that circuit which must
be replenished to prevent cavitation. To
:.'
accomplish this task, a fixed displacement pump
(gerotor type) is added. It is driven directly by
th e p ri me m over through the variable
displacement pump shaft..This Charge Pump .'.....
makes available a predetermined amount of fluid
that is used by the Pump/Motor circuit as
required to replen ish leakage losses .
.' .. -. ~~....... .-- .~ ~ ... ~~ e.·. . ..~~ ", •

Since the Pump/Motor circuit is a closed loop .

and either side can be high' 'pressu re, two (2) .&
check valves are needed to direct the charge , '1;,:
pump flow into the low pressure side of the -... :.
circuit. . -- ~ I:'~""

The pressure in the Charge Pump circuit is

limited by a factory set, direct operating relief
valve so that any fluid not being used is
discharged from the circuit over this valve,
through the pump and motor housing and back
to the system reservoir.

.•......
 .: -,>,~~,. -...-
... '. r·· •
~.

18 SERIES TANDEM PUMP

INLET PORT DRAIN PORT

1 5/16-12 SAE O,RING TYPE TOP & BOTTOM
1 1/16-12 SAE O-RING TYPE

MA.IN PORT-
BOTH SIDES
15;16-12 SAE
C·nING TYPE

CHARGE
PRESSURE
GAUGE PORT-
t _ ••
BOTH SIDES
7/16-20 SAE
O·RING TYPE
MAIN PORT-BOTH SIDES
',5,'16-12 SAE
O-RING TYPE

'!
CONSULT MODEL NUMBER OF UNIT TO DETERMINE SPECIFIC UNIT CONFIGURA-:ION

.,. CONFIGURATION AND SPECIFICATIONS -"~-~-~'.

...... .., ... --. .. : •.
--_..... _... -_._ ...... -.-- --'
'. ! '.~ i .; .-. ;:~. .. ; , •. '.~.,

2.3 in3/REV
' .

'.
- PUMP DISPLACEMENT:
0-3900 RPM
PUMP I NPUT SPEED:
CHARGE PUMP DISPLACEMENT·. .72 IN3/REV.
MAX~-b PE'R-AT IN G' PR ESSU R E: 3500 PSI .
CHARGE RELIEF SETTING: 100 PSI MIN. @ 1800 RP~,1
MAX. CONTINUOUS INLET VACUUM: SIN. HG.
MAX. CASE PRESSU RE: 25 PSI
25 micron (nominal)
. (j"::'.:'::::
. . .. INLET FILTRATION:

( . .
.....
. . -.'
, . -_.. .'. - ...
~.~

5,
..
,,~ , .. .
_ • ~'-: 'i ";.' -. ...
18 SERIES TANDEM PUMP
. it.- • ~ ~ ',&.. ",.." •• , '. e_ " • • • • •:.. ... ; ,", " ~;- . . . . . . . ._e • •

MINOR REPAIRS

NO .. DESCRIPTION GTY. 41

CHARGE PUMP (A)

Screw-Hex - -.. ' .. ":~ 2 . -
05
~-. 3 . . . --- .. Cover Plate .' ..-- .. -~ .... ' - ._-_._, '. _.-

4 Gasket 1 NO . DESCRIPTION -- ....::. QTY.

2 Screw-Hex. '.: -.1_' ~ .' !~ . ....
'
·2 . ,._--------------
~ ~ '., ..,.
.' '.~ ~ ......... ~ .. _ ...... ;~ .. ; ........ •.... -~·7"":'.~· .... ..:

5 Bearing 1 TRUNNION SEAL (C)

6 Housing-Chrg. Pump 1 30 Se~I-Lip 4
43 Screw 2
11
46
a-Ring .'.:
Pin-Drive
1
, 23
CHARGE RELIEF VALVE (B)
Plug-Hex.
,,
12 Charge Pump (G erotor) 1 22 O-Ring
44 Nut 2 21 Shim AIR
CHARGE CHECK VALVES (G) 20 Spring
7 Plug 4 Poppet
19
a O-Ring' 4
9 Spring 4 INPUT SHAFT SEAL (D)
10 Ball 4 41 Seal-Lip 1

56 ............ : -". .
. .~~.. ~~. : .. h' ~~:. ' ' ' ' . _ , . . . . . . . . _;,;,,.. .. _
. ':~'"
•• ~.
.:' ~
-: ._ ..... ", a.
;
.
 SECTION II: SYSTEM CIRCUIT DESCRIPTION

Control

SWASHPLATE CONTROL --- 18 SERIES

The variable displacement pumps and motors of the 18 Series transmissions are
mechanically controlled. That is. the control shaft is fastened directly to the swashplate
.... ·1
. "
so that any movement of the control shaft reflects in a direct. equivalent swashplate
movement and resultant change in pump flow and/or motor shaft speed/direction.

[CAUTION'

These pumps and motors do not have any mechc:nical or

hydraulic centering devices on the swashplate to return
the swashplate to a neutral position. As a result, the
s'Nashplate may move to a position of maximurT ratio.
Therefore, one must consider these parameter.s when
ceSi~;/irig the control system to be used with the j c .: ..:;~:~s
Var:able Pumps and Motors.

TAKE THE NECESSARY SAFETY PRECAUTIONS FOR YOUR APPUCATION.

It is necessarY to provide a force in the control system that will hold the swashplate at
the desired angle as internal forces may tend to move the swashplate in either
direction. A "fail safe" design, which will return the swashplate to neutral in the event of
linkage failure, is recommended.

Recommended minimum control force per 1,000 APSI of oper2.ting pressure:

18 Series 125 in. Ibs./1,OOO PSI

TAKE THE NECESSARY SAFETY PRECAUTIONS FOR YOUR APPUCATION.

::~·t·~
.......
.
. ,".:
. ...:'
." "

.. ..
..

. ... '

. :"j.> '~.;,'.\ ~. :
'-.(.
......_ - - - _ . , , _
.•_.. ----~---. ~ ________ ...---._.--- - '._--.-.,-_._........,.....
... __
. ~.! • ...

....... ~•• ~~.-:...-..-.-..-:--.--:-_;~. _____._••~._._.-:-•••.:;::"""

.. ', -.~.: :...:~.•...
.........~.~>;~
•.'-" ••• ,"'"7"
.. '-:"'
. • ':'""".-
 SECTION II: SYSTEM CIRCUIT DESCRIPTION
.'""; .: ...... ...
~
..

Control
-. : ' _." -'. - :<'.If· '-;'.-:. '.~;',. -.. :-. -.- •
The speed at which the output shaft turns is ,..---------------------.
proportional to -the position of the control lever' .. , - - ,: ?:~-'
and is infinitely variable between zero and
maximum speed. The direction of rotation 'of .-:.--.
the output shah depends on the position of the
~--
control lever in relation to the neutral position.

The variable displacement pump has a manual

control connected directly to the tiltable
swashplate so that as the operator moves the
control lever, the swashptate. tilts to a
corresponding angle resulting in fluid flow from
the pump. The fluid enters the fixed
displacement motor and pressure increases until
the motor (output) shaft begins to rotate.

When the swashc' :.::: (control lever) is at neutral, '.'

(zero tilt'angle') there is 'no' Stroking of the····i~ '--_ _._'._:_~_'_.-:_
...._.:._';_-::_:'~_.. _?_;.'._'_:_._ _ _ _ _ _----"1
internal axial pistons and th~refore, no flow _
from the pump to the motor~ .'" . .',
. .... - ",- ~.

The direction of motor (output) shaft rotation

depends upon which port the fluid enters the
motor. Reversing the direction that the
swashplate is tilted from neutral (zero angle)
reverses the output shaft rotation and hence the
direction of the mach ine.

Variable Displacement Motor .. ,... :.

~ .( ..~.. ~~ ..... "4':.'; ..• ..,j.;:~):-

The variable displacement motor is used to

provide a wider range of output speeds. It has a
tiltable swashplate which can be moved from
full angle to a lesser angle, thus reducing the
motors displacement so it will turn faster for the
same amount of input flow. Reducing the
swashplate angle (motor displacement) also ,r~
reduces the output torque for a given system
pressu reo

The variable displacement motor has a manual

control connected directly to the swashplate so
that as the operator moves the lever, the '-'
swashplate tilts to a corresponding angle. - -,

6
_.' ':l'. ~ . .'" .. ":'0 ":"~~'.-!..~~:: -.. ;·1>·.··· : ".,:, ..
"7:·.-:::~T·.·o"":·.:"""".:·~~~.~,":~;'-
.. _::-·~~::;-!;~~;~::';~~::~~~·~v~'t~:o:.;...:.:':"2\{:~")!IX. ~~I\:v;t~......-,,.::.,.".., ,--
...-.-,...".,..-----,--~--
 ::,";·'i"c\'""

SECTION II: SYSTEM CIRCUIT DESCRIPTION

Optional By-Pass Valve

BY-PASS
In some applications it is desirable to by-pass VALVE
fluid around the fixed displacement motor so
that a vehicle can be moved so that a vehicle can
be r.c'/ed short dist?:r)ces without running the
prime mover. This function is accomplished by
tne adaition of a screw in type valve at the
motor. When open (unscrewed) this valve
connects ,both sides of the Pump/Motor circuit
and allows the fixed motor to free wheel. This I
Ly-pass Va:ve must be f;jJly closed for nori:1z1
operation.

Reservoir Inlet Filter

c r-' '
('"
G "',
The reservoir is an important component of the
system. The suggested minimum reservoir total
capacity (in gallons) is five-eighths (5/B) of the
Charge Pump flow (GPM). The minimum fluid
It is imperative to insu re that only clean flu i
enter the hydrostatic transmission cir:~ il.
therefore, a' 25 micron (nominal rating) filter is
required in the Charge Pump inlet line. Thi.:
capacity should be equal to one-half (1/2) the filter shou Id not have a by-pass and mus: t-=.
Charge Pump flow. 'changed regularly to insure system reliability.

Example: Charge Pump flow equal to 2 GPM

Total Reservoir capacity should be
1 1/4 GAl.
Fluid capacity should be 1 GAl.
The Charge pump inlet port' in the reservoir
must be above the bottom of the reservoir and
must always be covered with fluid. The retum
port should be located as far from the inlet port
as possible to provide maximum dwell time of
the fluid in the reservoir. The returning fluid
should always discharge below the fluid level. If
an open or air breathing reservoir is used, the air
breather must be of sufficient capacity to
prevent contamination from airborne particles.
Heat Exchanger
The hydrostatic transmission shuuld not exce~s
2000 F as a continuous operating tempera:'yc.
To maintain this maximum temperature r.,ay
require the addition of a Heat Exchanger in the
line returning fluid to the reservoir. The
optimum Heat Exchanger should be capable of
dissipating a minimum of 25% of the maximum
input horsepower to the transmission.
Example:
-
Maximum Input Horsepower at
12 HP
Heat Exchanger Capacity at 3 HP

.. _,-----------------
•
,
,~J' .
·~:I
n
" 00

CHARGE
,
NEUTRAL REliEf
VALVE
I
FORWARD

\ CVlIND£ R BlOCK
ASSEMULV
FIXED
SWASUPLATE
en
-<
CJ)
-f
m
_-il4J----, CHECK VALVES
s:
n
~
n
-c
-f
C
m
CJ)
) r. · n
.;
:tJ
MOTOR
VARIABLE ."
-o
OUTPUT
SWASHPLATE SHAfT -f

fiXED DISPLACEMENT MOTOR :2

18 SERIES VAnlAnlE PUMP [ ; ] SUCTION flOW

,. AND FIXED MOTon II CHARGE PRESSURE
BASIC FLOW DIAGnAM
II HIGH PRESSURE

RESERVOIR
II CASE PRESSURE

_ ATMOSPHERE
 SECTION III: FLUID RECOMMENDATIONS

(.(
i :.
..
_'

Hydraulic fluids selected for use with the "F",. and (3) hydraulic transmission f>...J id
Sundstrand-Sauer hydrostatic transmission (type used by the Agricultural industry For
should be a quality product carefully selected combined transmission, hydraulic and wet brc-ke
with assistance from a creditable supplier systems). If a fire resistant fluid is requi:-ed,
following the guidelines presented in the "Fluid Pydraul 312 has been satisfactory.
Quality Requirements" bulletin, BLN-9887.
Most of the above fluid types have acce~ :.=.::>ie
Characteristics of the fluid selected should viscosity characteristics in the operating ran;:: of
include: 0 0 F. to 200 0 F. The fluids selected s--':u:~­
provide a minimum viscosity of 47 SUSat ~ . ~ ~
Viscosity Rust Inhibition F. and a maximum measured viscosity of 5.: .~~
Cxidation Anti Foam SUS at the lowest expected startup tempera:_:.
Iher-mal Stab ility Water Compatibility Typical fluid properties are listed on -:--.-:
Sr.~ar Stability Filtration Lim itations anached table.
L "'JW I"emperatu re Anti-Wear
r;uidil'l Properties Your best assurance for a quality produc: ' .. -.:
assistance that can be offered in its selec: ".;\
The following types of fluids have been used a fluid supplier. The major oil compani=~ c::.:-~
, successfully in the hydrostatic quite capable of providing suitable product::.
>1 transmission: (1) anti-wear hydrau lic . - -" -. .
oil, (2) automatic transmission fluid - Type

C C:

Typical Viscosity Pour Operating

SUS Viscosity Point Range
i
Fluid Type -. 00 1000 F 210 0 F Index of
.. (Typical of:
*''' .- •.•• -
Anti-Wear
Hydraulic I
Oil 7000 200 50 130 -: : -. -30 - 0-200 0 F.
'.
Type "F" 3200 212 57.2 208 ' .. -40 -15-200 0 F.

Hydraulic
Transmission
Oil 12,000 233 49 100 -35 0-200 0 F.

• Pydrau I
312 100,000 312 51 77 -10 50-200 0 F.

*Fire Resistant Fluid

/ ... .......
' ~'. .. :...
. {1-.:...________
.. . ,~ "".. ... I ..
.:-~.:
SECTION IV: START UP PROCEDURE
1. Prior to installing the transmission, inspect
for damage during shipment and handling.
Make certain all. circuit components
(reservoir, hoses, fittings, heat exchanger,
etc.) are clean prior to installing and filling
with fluid.
2. F ill the reservoir with recommended
hydraulic fluid which should be passed
through a ten (10) micron (nominal) filter
prior to entering the reservoir. Never reuse
fluid.
3. The inlet line leading from the reservoir to
the pump housing on the transmission must
be filled prior to start up. If gravity feed
does not fill this line, it must be filled
manually. Remember that the maximum
inlet vacuum at normal conditions should
not exceed 5 in. hg. Check inlet line for
properly tightened fittings and be certain it
is free of restrictions.
Be certain to fill the main pump and motor
housings with clean hydraulic fluid prior to
start up.
." • _.. • _ •••.••• 0" __
4. Install a pressure gauge (500 PSI) in the
charge pressure port with a short section of
hose and a snubber or needle valve to ~
( -', dampen pulsations. Charge pressures should ..-
read as follows after start up. 18 Series:
... ~ ·"~·100 PSI minimum @ 1750 RPM
·-_~·130 PSI minimum @ 3600 RPM
10
)
/
5. Start the prime mover and ru n at the lowest
possible RPM until charge pressure has been
established ... ,
CAUTION
Neverstart the prime mover unless the
swashplate is in the neutral (zero
angle) position or internal
transmission damage can occur. This
applies to any subsequent start-ups as
well.
6. Once charge pressure has been established
increase the speed to full RPM. If Charge
Pressure is not maintained at the proper
setting (it may increase but not, decrease),
shut down system and determine cause.
7. Run system at full input and output speeds
with motor output shaft disconnected from
__ , _ drive train or drive wheels ~ff _t.he gro~n.d)n
both directions and observe Charge Pressure.
8. Operate system for at least fifteen (15)
minutes then shut down and replace the
• ,.. __ _
..... inlet filter. Remove gauge and plug port.
Check fluid level in reservoir.
9. Transmission is ready for operation. ',., ..
-_ ...-.0:-_._--.-.--_ . . . . __ ._ . . _-.........,. ...._. --"~- _.
.- -
.. ,.'
'",
 SECTION V: SYSTEM MAINTENANCE
~ .--... -. '---"-."--'-""----.- -...... _-_. _ .. _...._4. _ _._-.· . ~;....;._
. .... _

The hydrostatic-transmission and related system Filters

components, no matter how perfectly matched
to the machine, will not give satisfactory service The charge pump inlet filter must be changed at
without proper and regular system maintenance least every 2000 hours when a sealed reservoir is
of the following major areas. used.

When an open (air breathing) reservoir IS U<":;

Fluid the filter must be changed at least every ~::-.
hours .
.':!
The hydraulic fluid should be changed at least
every 2000 hours of operation when a sealed The air filter on an open reservoir mus: :::
reservoir is used. replaced or cleaned every 500 hours.

An open (air breat~ing) rese-Joir should have Filters should always be replaced when cr.c~~~":~
... the h'ldrau lic flu id changed at least every 500 hydraulic fluid.
I
hours.

If the. fluid becomes contaminated with any Reservoir

foreign material (dirt, water, solvent, grease,
( G )
etc.) or has been subjected to abnormal
operating conditions, the fluid should be
changed more frequently.
The reservoir should be checked daily for proper
level, the presence of water (noted by a cloudy
to milky appearance or free water in boncrn of
reservoi r) and rancid odor (indicates excess:v~
Use recommended fluid only (see machine heat). When 'adding fluid to the reservoir, :.;s;;
specifications) . only the fluid recommended for the equipmen:•

•. 1

. ..
~ ~. - .

.. • • • f ' , '·0

....

11
_ . :, - ..
------------~--~~--
....-.--.-.
-"-~-:-. •... . .. ..,..
...,--~--....,.--.....-.......,:- •. c-.-..,..,......,...:--..'~. .• ": ..::: _: .. """,' '.0". _.",.0.::- !?;:.;.: i., ....... :. .', ' ..... .
SECTION VI: TROUBLE SHOOTING PROCEDURES

TYPICAL GAUGE INSTALLATION

SYSTEM
PRESSURE

EARLIER PRODUCTION
CHARGE PRESSURE
PORTS (BOTH PORTS
7/16-20 SAE
O-RING TYPE)

LAT=~ PRODUCTION

SAE O-RING
TYPE FOR
TANDE~ PUMPS)

~c
.- ". :. 'sYSTEM PRESSURE
PORTS (BOTH
PORTS 1/8 PIPE
THO OR 9/16-18
. SAE O-RING TYPE)

A. System Pressure gauge with 0 to 10,000 PSI Range

B. Charge Pressure gauge with 0 to 500 PSI Range
Snubbers are recommended to protect gauges. Frequent gauge calibration is necessary to insure accuracy.
Input speed should be at or near max. rpm when taking gauge readings.

12
' ••f

- .
 ,i r-'\
.~..
.•... ""'\
(.~.
:.,
....

. ~.
I: ;.' : ..... : 0.1

UI
m
o
-
-f
o
. .'. '. (
2
-<:
-i
REPLACE :a
CHECK CONTROL -01<- INSPECT CHARGE _ I)K-~ TRANSMISSION ·0
LINKAGE CHECK VALVES
(PUMP & MOTOR) c
~ . . OJ
r'
,DEFECTIVE
I DEFECTIVE
m
UI
~ :J:
o
o
REPAIR OR
REPLACE
REPAIR OR
REPLACE -2
-f

Gl
. I. .
I ;, .: ;, .
~ . SYSTEM JERKY
WHEN STARTING
. .,
SYSTEM OPERATES.IN ONE
'.:i' : t, ~:r DIRECTION ONLY
, 1 ;~: I il! ,I" I
. "I!
, .!.. .. ::' ,'-.

:'.' . , "~.". t!

j
. \
. '.,
 .. ~ ..
,'to ., (J)
INSPECT INSPECT m
CHECK OIL LEVEL OK OK OK
. CHECK CHARGE OK o
~ I~
HEAT BY-PASS
-
r I--
IN RESERVOIR
VALVE
PRESSURE -I
EXCHANGER
o
LOW DEFE{TlVE DEFE'CTIVE 2
t t -·<.
-f
FILL TO PROPER REPAIR OR REPAIR OR LOW :D
LEVEL REPLACE ~ .' , . ;. I.
.. t
,. REPLACE o
I c:
l'D
r-
"
I
m
fn
INSPECT CHARGE ~K INSPECT INLET :x:
~--~ RELIEF VALVE [- FILTER o
"
'0'
"
&.
.-:2
-f

:. G")
':
.."
REPAIR OR REPAI R on .12
REPLACE
REPLACE o
.' 'I I \ I .. '. REPLACE n
m
·C
'c
f
\ :u
t'
\ .•.. ...
• , 1 .. 1 ii REPLACE OK m
TRANSMISSION ~_ ·fA
,.. CHECK SYSTEM
(PUMP & MOTOR) PRESSURE ·I
·...
I
SYSTEM OPERATING HOT HIGH

I.
t c.~
· .,
.1 ,~

REDUCE :j
MACHINE
t
.I

LOAD ~J
REFERENCE SECTION VII FOR REPAIR PROCEDURES

~, .

.. , /
 SECTION VII: MINOR REPAIR PROCEDURES

- /. -. PUMP WITH SAE TYPE A AUXI LIARY PUMP MOUNTING PAD

C, ! '
.....
:,'

GENERAL PARTS IDENTIFICATION

NO. DESCRIPT10N QTY.

CHARG E PUMP (A)

1 Screw-H ex 2
.2 Cover Plate 1
3 Gasket 1 NO. DESCRIPTION OTY. i
4 Screw-Hex. . -. '.: 2
5 Bearing 1 TRUNN ION SEA,!- (C)
6, . Housing-Chrg. Pump . 1 15 Seal-Lip .....-- :'" - ',-: 2
'7 --Screw-Hex.--.-·--··· .-., --2 _,,0 _."_. __ '_~_ .----.
.!'",
•• _' _ _ ' _ ._ •• __ •
. . . . - -•••• ..,:
_ _, _ . _ • •_ _ _ _ _ ._.' ....

8 a-Ring' .J : :~: , =;: ~ 1 CHARGE RELIEF VALVE (B)

9 Pin-Drive 1 16 Plug-Hex. 1
10 Charge Pump (Gerotor) 1 17 O-Ring. 1
18 Shim - A/R
CHARGE CHECK VALVES (G) 19 Spring
11 Plug 2 20 Poppet
12 O-Ring 2
13 Spring 2 I NPUT SHAFT SEAL (D)
14 Ball 2 21 Seal-Lip

... ~
.;~ .:
'. : . . . :.::.• • • • • • • • • • • • '. • .... ... • •• ,eo t." .... '.,'
..... .eO • •'
'0 '0" .~. ':.,' :~.' ............: - •••••- ••
 J •• ~

~::I':; ..,~~~~~:~~ .vII: MINOR REPAIR_~.R:?~EDU~~S_. __.. . . ... . -.J ..... .-.
~., ..,.. .
PUMP WITH SAE TYPE AA AUXILIARY PUMP MOUNTING PAD

CHARGE PUMP C,l\N NOT BE

REMOVED WITHOUT MAJOR
DISASSEMBLY OF MAIN PUMP

:-;.
"'\

.i

GENERAL PARTS IDENTIFICATION

: .,
,
,~ ..•. : .. ~::; ..
e ' ••

- .__ e-:-=-..
NO. DESCRIPTION QTY. NO. DESCRIPTION QTY.

..CHARGE CHECK VALVES (G) CHARGE RELIEF VALVE (B)

11 Plug ." 2 16 Plug-Hex. 1
12 O-Ring 2 17 O-Ring 1
13 Spring 2 18 Shim AiR
14 Ball 2 19 Spring 1
20 Poppet 1

TRUNNION SEAL (C) INPUT SHAFT SEAL (0)

15 Seal-Lip 2 21 Seal-Lip 1

19
 SECTION VII: MINOR REPAIR PROCEDURES

AUXILIARY PUMP MOUNTING PADS

SAE TYPE A SAE TYPE AA

~TR'A,r;~T "~
Kf
CHARGE
-,~", t="t
"tJ:)~
\3.~
'--'

RELIEF VALVE t:S1

NOTCH ON BOTTOM
RIGHT HAND (CW FROM INPUT SHAFT END) RIGHT HAND (CW)

NOTCH ON TOP
'\

STRAIGHT
(-.:',.
( ~.

LEFT HAND (CCW FROM INPUT SHAFT END) LEFT HAND

ChARGE PUMP

'I Rotation Repair, ':. .':: :.i':-' '" : .. : :.:,!':.

...... " ......

Note the orientation of charge pump housing to The charge pump cannot_~ removed from units
insure proper assembly regarding input rotation with SAE type AA auxiliary pump mountins;
which is the rotation when viewing from input pad without major disassembly of main pump.
shaft end of pump.
Refer to Section VII I, page 32, for disassembly
RH (CW) Input Rotation
of charge pump forthis type of unit.
SAE type A - Straight side to left of • " • ~ •. f ·t.-'•• • .':

charge relief
SAE type AA - Notch on bottom (same
side as charge relief)
LH (CCW) Input Rotation
;-' SAE type A - Straight side to right of
charge relief
SAE type AA - Notch on top (opposite
charge rene~ _-_-.. '

" '
 .- ""'-'lIl' ."."UI. .J.!!Ig.$"~'lf.:
,~j~.~.
- - - - - - - . , . . . . -... :,..:-.,..~"f..--..;..;::::;.~;.......----

SECTION VII: MINOR REPAIR PROCEDURES

.J .... ,'.. , ' ". . . . . . . ".~ ~~~. ~~ :.

-- · · .. R eptacementofShatt &" Tni-n-rilon Sea·ts- ... -......~·~-~-.-. .-.-.;--';"';~-------":"--':"'-.------':'-:'---.-:; ..:. :/".

... ,-
------- ....
"" .......... ,,' ., " - '. . . '. .... . .. -.. .... \. ( ) ..

Lip type seals are used throughout these
transmissions. These seals can be replaced
without major disassembly of the transmission;
however, replacement of either the input or
output seal requires removal of the transmission
from the machine.
Pry the seal carefully out of the housing bore,
using care not to distort the housing or damage
the bore or shaft. Once removed the seal is not
reusable.
Prior to installing the new seal, polish the shaft
extension, wrap it in thin plastic and lubricate
with clean hydraulic oil to insure the seal is not
damaged during assembly. Slide the seal over the
shah and press into housing bore.

..... '.'
'-.c

Charge Check Valves

Remove slotted head plug (11) then slide the

spring (13) and ball (14) out of the end cap."
I nspect the ball and the mating seat in the' 'end
cap for damage. Remove any foreign material in
the valve area. Replace parts as required af'ld
reinstall into end c·ap.' In some instances' the
plugs. (11.) may not clear the charge pump
housing. If this happens, remove the four (4)
screws holding' the housing to the pump and
rotate it out of the way. Be certain to keep
proper orientation of charge pump housing to
insure correct rotation.

NOTE: Later production pumps have high

pressure relief vaJves which incorporate the '., .•..• y-: _ . . :... .:.:.. .

charge check function into their operation.

21
 • ; • .. ,~.A".I'" '''',.,", ' ...:\,.', '.",,,,
-.

SECTION VII: MINOR REPAIR PROCEDURES _, .. " 9 .. 9, .•.

'" ..... ;..".~:-

Charge Relief Valve

Remove plug (16) then slide the spring (19) and

poppet (20) out of the end cap. Do not alter the
shims (17) or interchange parts with another
valve. Inspect the poppet and seat in end cap for
damage and remove any foreign material in the
valve area. Replace parts as required and reinstall
into end cap bore. I
I

. 9_.. ...... . _ ... r •••

:,

By-Pass Valve .. ·r

.. . , .. ..-.. •... ...

.~.

Unscrew the by-pass valve (23) from the motor

end cap. Inspect valve and seat in end cap for
damage and remove any foreign material in the
valve area Replace parts as required and reinstall
into end cap bore. . ...

2.:
.... " :i 9
.' ••••

0"',:

.- -.-- .. ----_._-- : ,
SECTION VII: MINOR REPAI~ PROCEDl)RES

Applicable to units with

SAE Type A Auxiliary
Pump mounting pad only

Charge Pump

Remove hex. head screws (1 & 26) then cover
(2) and gasket (3). Remove four (4) hex. head
screws (7) and slide the housing assembly (5, 6
& 8) off the shaft holding the charge pump
(gerotor) cartridge (10) in place, then remove
the charge pump (10) and drive pin (9) from the
shaft. Remove the bearing (5) from the housing
only if replacement is necessary. .
Examine the wear surfaces of pump cartridge for
excessive scratching or heavy wear patterns.
Replace both parts of this cartridge if necessary.
Do not replace or interchange individual parts
within the cartridge. The drive pin (9) should
always be replaced. Visually inspect bearing (5)
and O-ring (8) and replace as required.
Coat both sides of pump cartridge (1 O} and
housing face with clean hydraulic oil. Install
drive pin (9) into hole in shaft, then slide pump
cartridge into place. Place O-ring {8} in housing-
then slide housing assembly (5,. 6 & 8) into
position 'over shaft. Orient ~ousjng to main"
pump for proper input shaft rotation and torque
screws (7) to 16-21 foot Ibs. 'Check for roper
internal assembly by slowly rotating-pump shaft
while tightening these screws. Replace gasket (3)
then install cover (2) and. screws (,. & 26).

23
. :... . :
~ ".:' .:; .' .... .
/. .' .... "
~~~. 1~~;""'",~~' ~.
(

SECTION VIII:
I

MAJOR REPAIR PROCEDURES I

I

1
The procedures on the following pages are for complete disasS€mbly and i
reassembly of the units. The equipment manufacturer should be consulted I
regarding any effect such repairs may have on warranty. I
.-.. . ... . ... . .. - ')
Cleanliness is the primary means of insuring satisfactory transmission life, I
( either on new or repaired units. Cleaning parts by using a solvent wash and
air drying is adequate, providing, dean solvent is used. As with any precision
t
equipment, the internal mechanism and related items must be kept free of ,
chemical and particulate contamination. .- -'
!

I
I
:

.. ,:.: ..... ...

.
.".-
-
~ ... ..

( _.
'--
SECTION VIII: MAJOR REPAIR PROCEDURES
--_.. -. -.... - .. - --'._'- _. . ..... .- - - -". -. -.. _-- -
~- . ,":V'

FIXED DISPLACEMENT MOTOR DISASSEMBLY

When the four (4) cap screws (30) are loosened,
the internal spring loading will cause the end cap
(33) to separate slightly. Loosen these screws
evenly to prevent distortion of parts. If end cap
does not separate from housing as screws are
loosened, tap end cap with soft hammer until
these parts separate.
~C
The end cap can now be removed from the
motor, however, be certain that the valve plate
(31) does not fall and become damaged. If the
valve plate tends to lift off with the end cap,
hold it in place on the end cap and remove both
parts together. If the valve plate remains on the
cylinder block, remove it at this time.

CAUTION The end cap is actually an assembly .consisting of

All surfaces exposed are critical and caution a bearing cup which is a slip fit in the end cap
must be used to avoid damage. and the valve plate locating pin (32). These parts
should be removed from the end cap:

24
. '.~ -.."T'.: •
--=. - -
.• ~ ----:-
• .,....
.•••"'"'"; •• .,-,..-,.-.~-:---::-......;.~.~
•• ..,. >: •...,...,..~,;-...,-.-,..,.,.
..... .. ~......
 SECTION VIII: MAJOR REPAIR PROCEDURES

( ,
'~\. ... '

CHARGE PUMP HOUSING

VALVE PLATE

ENDCAP @ /'

r·.
c_ ....
~.....
.-

:
",

VARIABLE DISPLACEMENT PUMP DISASSEMBLY

When the four (4) cap screws (30) are loosened,
t~e in"ternal sPring loading cause the' end C2P
(33) to separate slightly. Loosen these screws
evenly to prevent distortion of parts. If end cap
does not separate' from housi ng as screws are
loosened, tap end cap with soft hammer until
: these parts separate.
The end cap can now be removed frcr. -'-
will pump, however, be certain that the valVE
(31) does not fall and become damaged. if:'
valve plate tends to lift off with the end cc..t-
hold it in place and remove both parts togethe,
If the valve plate 'remains-on the cylinder block
remove itatthistime:,:,,;.~-·I! ':: ·:.~:;f:···';..:.

CAUTION The end cap is actually an assembly consisting c

All surfac~sexposed are critical and caution a bearing cup J37) which is a slip fit in the en
must be used, to avoid damage. cap and the valve plate locating pin (32). The~
parts should be removed from the end cap.

" .
_~ ;;'·i~(.:;",
.~ ... .
...•.• :: . ~ .~: :: .. ' .::: ;.
:. " ...
...

• •• Q. . . . . . . . . !' ......... .
0" ~.~.
.
--.0.', '~~;..-.-" ~,-,._::, -'!f.\'"J',- ::·.··~;.--n_-r.rs!J ·:··It.-:r:-~·.:;o:;~~·:';:.,~"'·f~c""fl(c-:..~""'.:· ..... :,,-;.:~ .•::'..:~!~ "'f.~••,._.,.~;:~ "
 SECTION VIII: MAJOR REPAIR PROCEDURES

( \
'- I

RETAINING RING

VARIABLE DISPLACEMENT PUMP DISASSEMBLY

(PUMPS WITH SAE TYPE AA AUXILIARY MOUNTING PAD)
.. : ..... , .... • ...• ~ ='"; ...... " : ...

_. After removing the retaining ring (28) the charge. :

~~. ~. pump ca~ be removed from the end cap (33) ... ,'. .....:,: . . . ..~... ~ •.• ~ .: •. oO.; : .. ',;1 • ; ! ',; :....... ".... ~
. .;._ .... Remove four (4) cap screws (7) and slide the .... . -:.. .'. ~ '.: '- ...
. ;7'::~~:.housjng assembly. (5, 6, 8, 29 & 43) out of the .-::.
'.. ~:.,_.' end ca'p holding the charge pump (gerotor)
cartridge (10) in place. '~L .". ..~; :.n .. i '. 4''": .~.:.
,-
Remove the charge pump and drive pin {9} from
the shaft (43). Remove the shaft and bearing
. .'.:J' , _ race, (29). If. bearing (5) is replaced, also press
off bearing' race (29) and replace. .

Examine the wear surfaces of pump cartridge for

excessive scratching or heavy wear patterns.
Replace both parts of this cartridge jf necessary.
Do not replace or interchange individual parts
within the cartridge. The drive pin (9) should
always be replaced.
"' C I

32

i!f~~;;.:i~:::.::;.~.~:~::l:~ire.t~~:~~.: . , ,~.' .<:~':" ..,,>,.:. :..:.,;:.,':~.. \:.~,.: .:,.. :.' ' .... " ...• ....
~ '..' ..
 SECTION VIII: MAJOR'REPAIR PROCEDURES

GSHAFT

BEARING eONEG

CYLINDER
BLOCK

"
.
,
~

BEARING CONE PULLER

( C
PLASTIC TO PROTECT CYLINDER
BLOCK FACE

HOUSING CYLINDER BLOCK

• .. ~."r .. "::

,
VARIABLE DISPLACEMENT PUMP DISASSEMBLY

·The bearing cone (37) must now be removed puller screw and shaft to prevent damage to :,i
from the shaft (41). A bearing cone puller as end of the shaft.
illustrated will provide a satisfactory method for
removing this bearing. It is recommended that this bearing be replac ~
as its roller cage is easily damaged durin
Protect the cylinder block face during this removal.
operation and use a spacer between the center

j.
. I
I

::.(
:., t{ '. ~.
. ,.';'.0 '!~= • ", . • . • --_. .. ......- .- - °
0
,.'. -:.

"0 '~'.' ...... •.•-.-.-.-~,...,.,.......,..-.•....,

..,-,-...,.....,...,..-. ••~.,.,.," X:-.. -:-......-:-:~~~.'~'.~
.•,."." ••:-.•:":' ....?'7'l~r:-"
•."-:' :"7.
.•. 7.....~ •••~.;-:':": •• ~~~~:--':'~.-:~~:::::
.• .-.'V7, ~.-~..........
: ...,...... :. ~
......... ••••-:'I"
•.•""'="':.:7 •.:-::"7
....:"'"'< .•.:-:-.-
S'E'CTION VIII: MAJOR REPAIR PROCEDURES
.' : ~.. . •.
VARIABLE DISPLACEMENT PUMP DISASSEMBLY
Slide the cylinder block assembly (36) off the
shaft while holding the external end of the shaft.
The pistons may come out of the cylinder block
bores during removal. There is no special
orientation of piston to bore that needs to be
maintained.
Do not attempt to disassemble the spring and
other parts from the center bore of the cylinder
block. The entire cylinder block assembly
34
T HOUSING
should be replaced if any of its components are
damaged. _, .' .....
Visually inspect wear surfaces of valve plate,
cylinder block and slippers for damage. Check to
be sure pistons are free in bores. '.
Remove thrust plate, (38) from counterbore in
swashplate (44). Visually inspect both sides for
damage and flatness. ..... j":''J'~.,
~-
~ (.
 SECTION VIII: MAJOR REPAIR PROCEDURES
·..: ..

(
SWASHPLATE

.......

'C·
. ......

e·:>
..: ..
VARIABLE DISPLACEMENT PUMP DISASSEMBLY

Using a 5/16 diameter drift punch, drive spring
pins (47) out of control shafts (45). The pump
housing is provided with a cast recess so that the
pins can be driven free of the trunnion shafts.
'.
.......... Drive control shafts out of sWashplate (44)
toward outside of housing (35). Once clear of
.0,
0'. swashplate bore, the trunnion shafts can be
removed easily. °The swashplate can now be
removed from tf1e housing.
The shaft 0(41) and bearing (40) 0can now be
removed from the housing. If be2r:-~
replacement is required, replace both the c:..;~
and cone of the bearing.
Remove needle bearings (46), if replacement is
required, by pressing out of bore toward outside
of housing. '''::. ~.~ _..... -:: . .~.:.;.. -. . . ~.~:r.:~ ~ .~~ ..;,:,. '; .

.... ..•. ~ ... . .

c·····
(0 >
-)
·.
.'
.'.
SECTION VIII: MAJOR REPAIR PROCEDURES ....
::;
~~ .:.; ----------------------------~----------..;...
P""
.~ 7-;. ···
....

x)

VARIABLE DISPLACEMENT PUMP ASSEMBLY

Prior to reassembly all parts, used and new, Press the bearing cup 'into housing (35) then
should be cleaned. Cleaning with solvent and air insert the shaft and bearing cone assembly (41 &
drying is 'adequate, providing that clean solvent 40). :.... :. ... :'-'.. . ....... . .. .
is used. ,'. .: . ': .. .. .. :.~. ~ ' '~".

Press needle bearings (46) into each side of

A supply of clean hydraulic oil is needed to housing until· flush to . 1/~ JDCh below
lubricate parts during reassembly, especially the coun~erbore for lip seals. . .... '';': . :.:~. v.. ..'
cylinder block assembly, thrust plate and valve t:1J j':f.~.r : _...~::!: ~:·:~t;::;J. . -\." .~ .. ,::"~nri",·~ :.:,:-~.-!i:.~.......:

plate. Place swashplate. (44) . into housing with

counterbore for thrust plate up. I nstall control
It is recommended that all gaskets, O-rings and shafts (45) and align holes for spring pins in
seals be replaced in addition to the charge pump swashplate and shafts using 5/16 drift punch.
drive pin, rear shaft bearing and swashplate pins.
 . SECTION VIII: MAJOR REPAIR PROCEDURES
. 1
,.

. c·.'.:.:::..·:··:..•..
(
~

VARIABLE DISPLACEMENT PUMP ASSEMBLY

I nstall new spring pins (45) through swashplate The swashplate should swing freely in
(44j and shafts (45). Use two (2) pins on each housing to 18 0 each side of center.
side. I nstall the first pin on each side until it is
1 1/8 inches below swashplate. Install second
pin until it is 1/8 below swashplate.
, ; ...
~, ..

.--. ... '. o· _ "0· "'.!'" . . , - ... , _..........

.. ....
~:
.'... ", ."

L)
37
.;.;~
"~'l; ·.:.~··t:'::···· . . ~i.~~.: .". ~..
~ '0

.•. '."
"'t-~::~""'
.•..-..............,.......,.~
. ".,..
.•.•::-o•••.'":."'.~,':"'":
... ::":'! ......,....
........
.. . .
' .........._ ,.....-:-:~~~~
•• :~ •• :~
••• -=-- •••~,.":-:'
.. ~•. -::-
""'Il'....•~.~.. a;;':-.'
,~,

.•••-:-.i:--l';-:-.........---"-"":--:---''"7"."'..
-- :.
••.::.--"~~--.. - --, ..-:-- - --.- _ .. -:--.
;'":"":,:",.,".7-'
-' .
.: .•'" ..
SECTION VIII: MAJOR REPAIR PROCEDURES

. ~ fiJ CYLINDER.BLOCK ASSEMBLY

/' ""Z

VARIABLE DISPLACEMENT PUMP ASSEMBLY

Lubricate thrust plate (38) with clean hydraulic installed a slight spring tension can be felt when
oil and insert in counterbore of swashplate(44). pushing on cylinder block.. . ..•
..... -
'. • '''I f
'r-.
~_'.
po •
. • :' I ' ,,' , -, ~:~ .... ' : ~ : . ',.: .........
.Assemble cylinder block parts if necessary and Lubricate exposed surface of cylinder block
lubricate with clean hydraulic oil. There is no with clean hydraulic oil. :. ...
special orientation of piston to bore that needs .-:', ... ~,.. ".
,
..
oil,' ~
.
·,f·." ... .:
"7,- "..' :- :.' .... . ..•

to be maintained. I nstall the cone of the tapered bearing (37) onto

shaft at this time. This bearing should be
Slide cyHnder block assembly (36) over shaft installed with an arbor type press for the most
and engage spline. Be certain that pistons and satisfactory results. Support the shaft and use
thrust plate remain in place. When properly caution during this operation to insure the
bearing does not contact the cylinder block.

38
 SECTION VIII: MAJOR REPAIR'PROCEDURES

( (

RETAINING RING

..
..

'·
~ ;.

c C
.. '.
.. ~.

VARIABLE DISPLACEMENT PUMP DISASSEMBLY '-'

(PUMPS WITH SAE TYPE AA AUXILIARY MOUNTING PAD)

Insert shaft and coupling assembly (43 & 29)

into housing and bearing (5 & 6). Coat both
sides of pump cartridge (10.) and housing faces
with clean hydraulic oil. Install drive pin (9) into " .'
hole in shaft, then slide pump cartridge into :::. '" BEARING RACE
place. PlaceD-ring (8) in housing then slide into
position on end cap. Orient housing (6) to' end
..... :~
. ::..-.~... 729
43 SHAEr-C~ARGEPUMP

cap (33) for proper input shaft rotation then . BEARING·

5 .. ' ' ..
install screws (7) and torque to 16-21 foot Ibs.
The charge pump must rotate smoothly after ~ ,CP HOUSING"
torqu i ng cap screws.

(..... C":
'--/~~ .~

39
... .. ;.~

-'~~;~\'. ...};:;~
::'"~--- .........- - . - .'~'-'-
. • -. ••••,.:--.. 'X'.<~
..........--.0:".-.-:-.'7';; .. ~.• ~
..• '''''
...':'':'' ... -:o:r.
.. ,.... ....-.-•.. ~
•..':-".~--:-:-..-...,..,--,-..
~:
SECTION VIII: MAJOR REPAIR PROCEDURES

VALVE PLATE

ENDCAP~

~(

. ;' .• "..

VARIABLE DISPLACEMENT PUMP ASSEMBLY

, •• 0 • •~ 0

'_ .. .;

0 • • .,. :. '.~".':: ;:".; •••

Insert locating pin (32) and bearing cup (37)
into end cap (33). Lubricate the slotted side of
the valve plate (31) and slip it over the locating
pin and protruding bearing race. The motor and
pump valve plates are interchangeable in the 18
Series units..
Install four (4) cap screws (3D), and tighten
alternately until the end cap and housing are
pulled completely together. Torque screws to
45-57 foot Ibs. Check for proper internal
assembly .. by rotating pump shaft while
tightening these screws. .~ .. ;".:.. :~ ~ ;.~ .... ~. ..

Place the gasket (34) on housing, then install the

end cap and valve plate. Hold the valve plate so
it does not drop ~~. during assembly.

40
 "SECTION IX: G ENE RAL PAa:ilS IDE NTI FICATION ' ';:,:"...~'. ," ... ' ." ...."-".

(~; FIXED DISPLACEMENT MOTOR

...

"
,
f
I

I
("
"r

REF NO. PART DESCRIPTION QTY.

22 SEAL-LIP, OUTPUT 1
23 BY-PASSVALVE 1
24 BACK-UP RING ...; 1
25 O-RING
- 1 '.
."
"

30 SCREW-12 PT 4' -; '. ::. ...

".::: f ..
" " 31 VALVE PLATE .' . 1 _. -
'.~.

" 'i
"
".
32 HEADLESS STR PIN 1
33 END CAP 1
~
. :

..
34 GASKET ! ...
1
," "~' 35 HOUSING 1
"

.
36 CYL BLOCK ASSEMBLY 1
"\ 37 REAR BRG, CUP & CONE 1
38 THRUST PLATE 1
39 SPACER 1
40 FRONT BRG, CUP & CONE 1
41 SHAFT 1
42 RETAINING RING 1

For part numbers refer to Parts List for specific Model number.
49
- .....-'~... -:."
.> . >.;>..~. ~.. ...•..•. ""...•.• ~ •• ~.. ,:~.. ~.,.: ....•
 ..... , ",;,,~::(:::~;;:~:~~,' ,

"
"
.: • . I ' .
PE'AA,2 OR
SAE TYLT AUXILIARY
'" BO,
PUMP MOUN •
T . ~':"en
<~;m
».
:o'~ 0
- :-f
»
to
-0
o~ _2

»
~
en
..C)><
~ m
~'2
m'm
~ :Jl
"'0 »
~ r-
"'0
'»:Jl
"

, , -f
't/)

C
m
-
:2
-
-f

-
,
=."

;~
'0

1
"
j
~

l
!~~~AAY'PUMP
I
I
PE A 2 flOLT,
J . MOUNT.
 SECTION IX: GENERAL P.ARTS.IQENT~FICATION

VARIABLE DISPLACEMENT PUMP

REF. NO. PART DESCRIPTION QTY

1 Screw - Hex. Hd. 2

2 Cover Plate 1
3 Gasket 1
4 Screw - Hex. Hd. 2
:.,
;" .. 5 Bearing - Needle 1
6 Housing - Charge Pump 1
7 Sr:rew - Hex. Hd. 2
8 D-Ring 1
9 Pin - Drive 1
10 Charge Pump (Gerotor) 1
11 Plug - Slotted Hd. 2
12 D-Ring 2
13 S;:r:ng 2
14 Bail 2
15 Seal- Lip 2
16 Plug - Hex. 1
17 ~~c. O-Ring 1
18 .~ Shim .... AIR
19 : Spring .-' 1
"0
. - 20 .Poppet 1
21 Seal - Lip, Input 1
26 Coupling 1
27 Bearing - Ball .1
28 Retaining- Ring 1
29 Bearing Race 1
30 Screw - 12 pt. hd. 1
31 Valve Plate 1
32 Pin-Locating 1
33 End Cap 1
34 Gasket 1
'35 Housing "-.-.;': '~.~- '-:~~-:-: ..~. 1
36 Cylinder Block Assembly _. 1

- ....- ."-," 37
38
Rear Bearing (Cup & Cone) .
Thrust Plate .-:-:' "-', ,- ,:.. -:'" '.
1
1
40 Front Bearing (Cup & Cone) 1
41 Shaft 1
43 Shaft - Charge Pump . 1
44 Swashp late ." ,- , 1
45 Control Shaft 2
46 Bearing - Needle 2
47 Pin - Swashp late 4

.":-
-........."..

For part numbers refer to PartS List for specific model number•
... .".'-
-i
~':.~ . ~"" _ i.

~ ••
:'
. -~ ..~".: ~ ~-. . ..
.:) _ ••p.

------ .. ~.--,-,-----~~.-~
--"0 • • • "
~ :~
SECTION IX: GENERAL
~'....
PARTS IDENTIFICATION '..
, ..
-"
.. ....... . ..:.....
.~ -:
:.~: .. . i.
::'.' ':' -VAR-iABlE-C)I'SPLACEM-ENT MOTOR'-" . '.--." --_. . ...... "-."
••• : '• • _ ..... ," ,.' ." • • •• -# .,- .:'"" • - . . . . . .- _ .. ___ ••• 0 •• , ....... .

~
.=..

. .. ,:::---:-,

"! ....

·~rl
\.
,
 SECTION IX: GENERAL PARTS IDENTIFICATION

( ( VARIABLE DISPLACEMENT MOTOR

REF. NO. PART DESCRIPTION QTY.

22 Seal-Lip, Output 1
23 By-Pass Valve 1
24 Back-Up Ring 1
25 O-Ring 1
30 Screw-1 Pt. 1
31 Valve PI e 1
32 1
33 1
34 1
35 1
36 1
37 1
38
40 1
41 1
44 Swash plate 1
45 .. __ . --- .• - h Control Shaft _._ ..- _........ - -- e' .-
2

( c 46
47
48
49
Bearing - Needle
Pin-Swashplate
.Washer
Screw
:" ... : .- ....... ~ -. "....,. 2
.. -4' . .-'; '. :.: '.
1
1
~

50 Nut 1

'.' -'. , ...

. '

". i!" .,". ..' . :, - • 0" :', •

.. ,""....
........
.;
,"<11#
' . '

~
..'
' ..• ' i:

(
)
C '::",

)
F~r part numbers refer to Parts List for specific model number.
l,
.;~~ .... ',::. -_ ..... .. - . . ., ...... ':
".:.1
' .. ~
... • ':' ... .:., ~I' •• , ... :" • ...
.:. :~.: .. ....... ~

4-~' _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _........_...... ,. _. --....,......._-:--. _ _ _ ....- - . - - . - - - - - . . - - - - : - - - -

:- '

., .... ,":'_ E::.}..'Ii ~ ~ '.' ::: ~;. . .

'. _.... :.
'- "/.
.. .:.-". ~,
_'_"0" '" " ;.,. , -

18 SERIES TANDEM PUMP

..... _ _ .... , _.. _ _ ,t.. _ _ _ _ _ , _~. ____ - _ ' _____ ~ ~ • ___ ,

r-----------------------~--~

CHARGE CHARGE RELI EF CHARGE

CHECK CHECK

CIRCUIT DESCRIPTION

The 18 Series tandem pump consists of two (2) A fixed displacement (gerotor type) Charge
variable displacement axial piston pumps, Pump is driven by the common shaft and
driven by a common shaft. Each pump is provides fluid to both closed loop circuits,
designed to be connected in a closed loop to a through the Charge Check Valves, to replenish
fixed displacement motor. Each pump can be losses and prevent cavitation. The charge
controlled independently so that the output pressure is limited by a single Charge Relief
speed and direction of rotation of the motors Valve. . l
are also independent. -

11. _

54
..
-......~; .. ;-..- .. ~. ; ....- ..
-" -,
:··~~·~t:?i0~~.··
.. - ..,'.,".. ~ .' ..... .J • • '
 18 SERIES TANDEM PUMP

cr.

c_ ( ~.
'
>-":
... ',

.........

~' MAJOR REPAIR

. ' ..

The unit can be separated into two (2) pump After separation. each pump section can ::~-:
sections after removal of cap screws (54). disassembled following the proced'Jr::
." outlined in the Major Repair Section for t; ~
..,:-. .~
-

Variable Displacement PUmp.

J~. '., . ". ~ ~~.

...

."

c )(ill? , . -,~. '. ~ r< .

....., ) "

~\
~:... " _ . . . . . . . :::;~.' ·.;:~:f~.>.·.:". • '~:':"' .. :~ '. ,.4 . : •.;....:..::... :,;
:.:~t.--.-.· . . . .-,...........----,-___~..-.-~~...-.-~",--~--:---""", .. -"--"-""-.---:- -~"-""".--'----- --..:..-------
-=.: .'
...... ' .. . .......;,. .. - '. .~ - .

. "

. ,: :'..:, ~ - "' ........... .

. - ..-
"

18 SERIES TANDEM PUMP

~ .()
58

."
. : :~"~.. -.. :"}~~
"
..•. :
18 SERIES TANDEM PUMP
GENERAL PARTS IDENTIFICATION

REF NO.
- - - - -PART DESCRIPTION --....;.,:.QTY

2 SC R:S~1- HEX. HD • C;:..? 2

3 PLATE-COVER 1
4 GASKET-COVER 1
5 EEAR:~G-NEEDLE 1
E 1
~ .. 7 PLUG-CEECK VALVE 4
8 "0" RING 4
9 SPRING-CHECK V'J._~VE 4
10 B;"LL 4
11 "0" P..ING 1
12 ASS' Y
G:=:R8':':'~ 1
13 E?ID C~":l - PUMP 1
1:- PLUG-STR.THD. f-EX 4
17 CON~~ECTOR 2
18 PLUG-PIPE _. "'.'
4
19 VALVE-RELIEF .... 1
20 SPRING-CHG. REL. VALVE·' 1
r··
c····
...
:.
:-'
I 21
22
SHIMS
"0" RING
.... ' AIR
1
23 PLUG 1
24 PIN-S'I'R. HD'LESS 2
25 GASKET 2
26 PLATE-THRUST 2
, 27 SHASH?LATE-VAR. 2
.' 28
29
PIN-S?RING
FRONT BEARING KIT ASS'Y
8
1
30 SEAL-:"IP 4
31 BEARING-NEEDLE 4
. )
32 SHAFT-TRUNNION 4
33 HOUSING-VARIABLE 1 . - . --- ."'.:::'
35 PLUG-STR.THD.HEX. 2
36 TUBE-ASS' Y ·P. 1
37 . RING-RETAINING -: 1
38 GASKET 1
39 END CAP - PUMP 1
40 HOUSING-VARIABLE 1

,
"

- -'" -.:..L........
.. . :
....:-. ..:'
",.
~

.......
'. ••e' e~:' t ' , . : ... ~ •• ' . : .... : . ' ~ •• ' • . ...... :
, "~, " .. .' .
~
 •• -!,
..............

~~/ ,'~iD:":~~:;': .'.. ..' .-' . . ' ~ .. ·'=1~r~.~.q ~:":~~'1:: ~~r ~::?~.~~:':~~. :.,'
.:"=;...... . 18 SERIES TANDEM PUMP
~~ ~ir-:-,':. }~~::.' ~ :;-~.~..~ :~ ': .:. .
. GENERAL PARTS IDENTIFICATION
i

' .
--~...,.> . -.--- . -"'-~' - _...- . -'-'--'
REF NO. PART DESCRIPTION QTY

41 SEAL-LIP 1
42 SCREW- SOC HD. CAP ... {OR) 8
SCREW-12 PT. CAP 8
43 STUD 4
44 NUT 4
45 SHAFT-CHG.PUMP DR. 1
46 PIN-STR. HD'LESS 1
47 BEARING-BALL 1
48 RING-RETAINING 1
49 COUPLING 1
50 PIJ..TE-VALVE 2
51 CYL BLOCK KIT' 2
52 REAR BEARING KIT ASS'Y 1
53 SP..AFT- PUHP 1
54 SCREW-HEX HD 2
55
56
WASHER-PLAIN ;' ...
.. : 2
. SHAFT-PUMP 1
57 COUPLING .~ 1

SERVICE PARTS KITS AVAILABLE

CHECK VALVE KIT _, . -': :_~.: . :: 4

(Contains' Ref. N;. 7~ 8, 9, 10)
CHARGE RELIEF VALVE . . : -r"-' . 1
(Contains Ref. No. 19, '-'20 ~ .... 21', 22 ; .. , .
23)
.
'. ".r. ..• "~.- • . . .--
. •. ~rt"': ~,! ...~ ....., ....... !. _ ~, ' -:
CHARGE PUMP KIT .";':;.; "';:"":~ ........... -'. ·1
(Contains ._Ref. No.1," 2, 3 ~ . 4 ~ 5, . -...
. .':. 6, 11 , ···12;··46)·-.~~;
. • •• .. _r ..
~-., ~ . .•.. :',

:-. . . -,;. ,. ...... ~.

For part numbers refer to Parts List for specific model number. .

--, .
~

•.
" .".
. _a'• •
.. •.,' •. ---
~I/l~' ~: -: :::;:~::f:.I:; i{i;,. ;, -.:-
 REHR~iRi~ RA
WORLDWIDE HYOHAULICS SEAVISCR.IPT
MOBILE HYDRAULICS DiViSION
1700 OLD MANSFIELD ROAD MOBIL'E
WOOSTER, OHIO 44691
(216) 2822010
Telu 98·5J35 S15S Series Hydraulic Gear Pumps 64·756·5
ISSUE: 1-80

I
IjI

5155 SERIES
HYDRAULIC IYIODELS
GEAR S15S-4 5155-7
PUMPS S15S-5 5155-9
Refer to the parts list section for an explanation
5155-6 5155-10
of coding used to make up complete ca talog
numbers.

(~'r
(1
 '"
··.,;.1.

PREPARATION FOR D1SJ\SSEMBLY

Overhaul pump only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will
damage the highly mac;,;j'"jed sL;:~2:es :nd will result in leakage or premature failure of the pump.

Before beginning disassembly, scribe match marks on the body and cover to insure that the pump will
be reassembled in the same manner as it was shipped from the factory. If the body or rear cover is
replaced during overhaul, scribe a match mark on the new part in the same location as on the part it
replaced.

DISASSEMBLY OF PUMP

NOTE
All reference numbers refer to items illustrated in the exploded view pro-
vided with the parts list section of this publication.

1. Clean outside of pump with a good grade solvent and dry thoroughly.

2. On models with splined drive shaft, proceed to step 3. On models with keyed drive shaft, remove
drive key (12) and snap ring (11) from drive shaft. Using a file or stone, remove any bu rrs from shaft end
or key way.

3. Secure unit in vise (use light clamping pressure) with shaft end down; remove cap screws {1} and
washers (2).

NOTE

During disassembly, take special note of the wear patterns on the wear
plate (8) and thrust plate (6). Relate these patterns to the inlet and
outlet sides of the pump. The large port in the rear cover (3) always
corresponds to the inlet side of the pump. The inlet side can be further
identified by the gear contact pattern in the gear bore. The wear plate
(8) will have a somewhat heavier wear pattern on the inlet side. The
thrust plate (6) will also have a pattern that can be established for re-
assembly. Also note that the long journal of the driven gear (13) is
toward the front of the pump. " ..
4. Separate rear cover (3) from body (15) by supporting pump, shaft end up, on mounting flanges
and pressing on drive shaft end in arbor press.

CAUTION

Use one hand to support rear cover from underneath, since cover and
internal parts will drop suddenly when dowels are disengaged.

An alternate method of removing the rear cover is to pry simultaneously with two large screwdrivers in
the relieved areas between body and cover.

2
( ---
)
 ( CAUTION

At no time should screwdrivers be inserted further into pump than the depth
of the relieved areas. Any burr or upset metal must be removed from the
body (15) and/or cover (3) after this operation to assure a good seal between
borly and cover.

5. Hulding pump shaft end down, remove rear co'ver (3). Dowel pins (7) may remain either with
body or rear con:;,.

NOTE

Cover gasket (5) and thrust plate (6) mayor may not remain with rear
cover. Should they remain with body, remove gasket and lift out thrust
plate before proceeding.

6. Lift out driven gear (, 3), drive gear ('4), and wear plate (8).

7. Invert pump body with shaft seal up. Remove shaft seal (10) by prying it out with a large
screwdriver.

CAUTION

Care should be taken not to damage the shaft seal bore as this would
result in seal leakage.
-....
c PARTS INSPECTION

,. Wash all parts and dry thoroughly.

2. I nspect wear plate (8) and thrust plate (6). Replace if scoring or uneven wear is observed.

NOTE

Somewhat heavier wear pattern is normal on the low pressure (inlet) side
of the wear plate (8). However, there should be no heavy scoring in this
area.
;t
I 3. Remove pressure loading seals 9 and' 6trom wear plate. This seal may be two-piece or one-piece design. In
I
I either case, discard old seal or seals. All replacement seals are two-piece design and should be installed into
,.! groove. See view. The seal should extenda minimum of .127 mm beyond surface of wear plate. Do not push seals
below wear plate surface at any point.

4. Inspect bushings in body and cover. Replace cover or body if bushings are heavily scored or burned.

5) Inspect gear journals and faces. Replace if faces or journals are scored or worn, or if shaft journal wear
exceeds .025 mm.

6. Inspect body for wear and scoring. If gear contact wear on low pressure side (inlet) exceeds .127 mm depth,
replace body. If the body is usable remove wipe burr with suitable burring tool.
(j
)

I 3
 (

•
 r----------------------.--..----------------------.
( I PUMP REASSEMBLY

NOTE
The installation of new parts contained in Seal Kit No. 1501-635-007
recommended at each overhaul of the pump.

o 1. Place body (15) on flat plate with shaft seal bore up. Install new shaft seal (10). Press seal ~ntil it is
to approximate depth shown. Pack the area between the double lip of the seal with Lubriplate or equivalent.

2. I nvert body so that gear bores are up. I nstall wear plate (8) in bottom of bore, making sure that
pressure loading seals 9 and 16 are positioned properly in seal grooves and installed against bottom of bore
surface. '

3. Lubricate bushings in body and face of wear plate with SAE 10 oil.

* shaft4. sealApplyfromLubriplate or equivalent to outer surface of drive shaft installation sleeve. Insert sleeve into
front of pump until sleeve contacts drive gear bushing. Install drive gear(14). Install driven
gear (13), with long journal toward front of pump.

5. Lubricate rear gear faces and journals with SAE 10 oil and install thrust plate (6) in its original
position, bronze face toward gears.

6. Apply a small amount of grease to rear cover seal groove and install new rear cover seal (5) into

c groove.

7. Lubricate rear cover bushings with SAE 10 oil and install rear cover (3), matching scribe marks on
cover and body.

·
;
.. 8. Position pump with shaft end down, install the rear cover (3).

9. I nsert cap screws ( 1) and washers (2); torque to 34 to 38 ft-I b.

10. On models equ ipped with keyed drive shaft, install snap ring (11) on drive shaft and install drive
key (12). .
·· ,,
r, 11. Check that drive shaft turns with adjustable wrench without evidence of mechanical ~ind.
i~
:~
I·,
, ,

BREAK-IN PROCEDURE

Test stand method:

1. Run pump for 1 minute at minimum pressure.

2. Raise discharge pressure to 34.5 bars for 5 seconds, then lower to minimum for 5 seconds. Continue cycle
for 1 minute.
. ....... ,. . . :..
~: ~.

3. Repeat step 2 but increase pressure in 34.5 bars i,ncrements until maximum operating pressur~ Is obtained.
Chec:, ::.::., tj _,~~. me'h()~ :"li!?:hle.

'"

4
( )

(-
 Alternate on-equipment method: '".

1. M!')unt pump on equipment and operate for 2 minutes at 'minimum pressure and one-quarter
engine speed ..

2. I ncrease discharge pressure to relief setting with control valve. Hold for 5 seconds and release.
Continue cycle for 2 minutes.

3. Repeat step 2 for 3 minutes at one-half engine speed.

4. Repeat step 2 for 3 minutes at full engine speed.

5. With engine at idle speed, check pump and hydraulic system for leaks. No shaft seal leakage
sufficient to form a drop is permissible. No external leakage is permissible.

Output flow of an overhauled pump should meet or exceed the following:

DISPLACEMENT SPEED PRESS FLOW·MIN GEAR WIDTH

MODEL (!N 3 /REV • CM3/U) (RPM) (PSI· BARS) (G PM • LITERS/MIN) (INCH ES • M M)

S15-4 0.43 7.05 1800 2500 1,'2 2.4 9.1 0.44 11.18
S15-5/.~o 0.58 9.50 1800 2500 172 3.6 13.6 0.59 14.99
( S-1 5-6 C)~,
S15-7.,/<;)·
0.68
0.81
11.14
13.27
1800
1800
2500
2500·
172
172
4.3
5.4
16.3
20.4
0.69
0.93
17.53
23.62
S15·9 1.00 16.39 1800 2500 172 6.8 25.7 1.02 25.91
S15-10 1.20 19.66 1800 2500 172 8.4 31.8 1.22 30.99

Below 1s a sketch clar1fy1ng the recommended shaft seal press1ng tOOl, proper
press depth of shaft seal, and 1nstallat1on sleeve for assemb11ng keyed shafts.

I.Hvt ;SHAn
J.StALUTltlf
SUEVE

lion:
DIIIVE SHAF'T IlISTAUIoTlon
SU!vt II.1>U TIIICJ(JIESS
'fltsS SHAn SJlClJUl U APPJlOXIIVoTtt.r
StAL III TO .H_
tHIS DIX. CO .010 inch)

*
Caution: Break-in ~f the pump if a new body was replaced could result in wipe chips (which is normal) to be
n)
.
expelled from the outlet of the pump. These small aluminum chips could go thru the system, precautions
should be taken to assure these chips will not result in other component failure .

"
5
."
,- ~ ... ..
'.'" .
(~

(
 PARTS LIST

This parts list covers pump models in the S 15S series. Before ordering replacement parts, it is necessary
to know the pump catalog number. The catalog number provides a key which explains and differentiates
the pump features. Catalog numbers can be determined per the following example. to

S 15 S -4-A-H-2~3-R

GEAR PUMP~ T • LROTATION VIEWED FROM

SERIES NUMBER~ DRIVE END

R-Clockwise
L-Counter-clockwise
NATIONAL STANDARD - - - - - - - - - - '
B-Great Britain PUMP CAPACITY in -
G-Germany gallons @ 2000 RPM '-- DESIGN NUMBER
S-Uniteu States & 100 P.S.1.
~ DRIVE SHAFT OPTION
PORT LOCATION - - - - - - - - - - ' " l-Spline
A-Ports in side MOUNTING PAD - 2-Straight, keyed .. short
D-Ports in rear OPTION
7 -Straight, keyed-long
E-SpeciaJ H-S,oIE "p," 2·blJlt

( The parts list provides replacement part numbers for all pumps covered in this publication. Some of the
parts are common for all models. These parts are listed separately under the heading of "s 15S ALL
MODE LS". Parts that differ for the various pump models are listed under their specific model number.

To determine the number of a particular replacement part, first find the part in the exploded-view
illustration and determine its index number. Then check to determine if that index number is listed
under the heading "S15SALL MODELS". If it is, the required part number will be found beside that
index number. I f the index number is not found under this listing, check for it under the model num-
ber of your particular pump. The correct part number will be listed beside the index number in that
location.

<-;oJ Y
l.!
I

11 6
c)
( .~
';'-
OUTLET LARGE PORT "INLET"

Do not force nylatron

sea! be! ow su rface
14C

,
-4
5

c NOTE: This unit positioned for lett hand

rotation. Rotation can be changed to right
Nylatron 16

by rotating cover 3A or 38 180°.

INDEX QUANTITY
NO, PART NUMBER DESCRIPTION REQUIRED
S 15S All Models
-
1 60101·038 Hex Head Cap Screw 4
2 61201·003 Washer 4
3A 1501·542·001 Cover·Side Port (A) 1
38 1501·542·002 Cover·Rear Port (D) 1
4' 76105·003 Pipe Plug 1
5 62102.004 tt Gasket Seal 1
6 150 1· 047·001 Thrust Plate 1
:7 69201·001 Dowel Pin 2
:'\ '8 1501·048·001 Wear Plate 1
9 1501·077-003 * Spacer 1
10 1501.076-001 It Shaft Seal 1
11 71121-002 It
Snap Ring (Keyed Shaft) 1
It
12 63101-005 Woodruff Key (Keyed Shaft) 1
! . 1501-835-007* Seal Kit (includes items identified
:
by asterisk (tt) above)
.. 16 ........... '" 1501.077.002 It Nylatron 1
t: 1501-635"{)01 Design 1 Seal Kit

7
 ( \
')

;'~~:a'!.=."""~'l':"z.'YJ7'f'_.=~,""",-"'-~~,.u:-!Y»~'''''''t.'l.....-""._,,, •.
~._""~",,, ,___ .~.~_~_.~~. ~
..
_ _ _ _ _______ ~ _____ ~
( INDEX QUANTITY
NO. PART NUMBER OEseR IPTION REQUIRED

Model S 155-4

13 . 1501·032·001 Driven Gear . . . . . 1

14A 1501-031·001 Drive Gear (Spline 1) 1
I .., t) ; ........... ;-
'~1
~
r'r~
> ~ \.... ~""\"i\··~: G~.2r ! ~/ ~\'2G 2~ 1
1 r~ 1 I
14C 150 1· 03 1- 0 13 Drive Gear (Keyed 7j
15 1501·553·001 Body . . . . . . . . . 1

. Model S 15S-5

13 . 1501-032·002 Driven Gear . . . 1

14A 1501· 03 1-00 2 Drive Gear (Spline 1) 1
148 1501·031-008 Drive Ge2r (Keyed 2) 1
14C 150 ,. 03 1· 0 14 Drive Gear (Keyed 7) 1
15 1501·553-002 Body . 1

Model S 15S-6

. 13 , 150 '·032· 003 Driven Gear . 1.

14A 150 '·03 1· 003 Drive Gear (Spline 1) 1
148 1501-031·009 Drive Gear (Keyed 2) 1
:.
14C 150 1. 03 1· 0 1 5 Drive Gear (Keyed 7) . . . . . 1
( ·15 1501·553·003 Body. . . . . .. 1

Model S155-7 .'

13 1501·032·007 Driven Gear .. 1

14A 1501-031· 006 Drive Gear (Spline 1) 1
148 150 1· 03 1· 0 1 2 Drive Gear (Keyed 2) 1
'14C 150 1. 03 1- 0 1 8 . Drive Gear (Keyed 7) .1
15 1501·553·004 Body . . . .'. 1
, ......... ..
'~.' . .
Model S 155-9
,.
:-:;;:1'3 ,. 1 .'
1501-032·008 . Driven Gear. . ....
14A 1501·031·004 Drive G ear (Spline 1) ...... , 1
14B 1501· 03 1· 0 10 Drive Gear (Keyed 2) .' 1
.14C 150 1- 03 1· 0 16 Drive Gear (Keyed 7) 1: :.
15 1501-553·005 Body ...•
"
Model S15S-10
••" .. '0" . ;

13 1501·031·009 Driven Gear 1; .

14A 1501-031-005 Drive Gear (Spline 1) 1 :'.'
148 1 501· 03 1- 0 11 Drive Gear (Keyed 2) 1,.; .•
14C 1501-031·017 Drive Gear (Keyed 7) 1 ;: :
15 1501·553·006· Body· • • • . . • • • • 1

.. :'.,

8 Ulho U.S.A. M.H,O.80 2'IJm :•. c.P. 1-80

....
 (" )

'"

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 ':,~;::,< . ... ,....... .
', : " .
" ." \:.::::"'>::"\' ~": " . .
. ...:.......
--..... ':'~" .,
,..ii:~, ' ~ .. .... ~ --'~'

C',

en
CHECK OK OK OK OK m
I

n
----
CHECK CONTROL INSPECT CHECI< CIIARGE CHECK :TEM
OIL LEVEL ~ ~

-
.- 1---
LINKAGE nY-PASS VALVE rnr~sunE PRE: tE -f
IN RESERVOIR
0
I I I I 2
LOW DEFECTIVE DEFECTIVE LOW LOW
t t l
,
"

~
<
'.;

" . -f
FILL TO PROPER REPAIR OR REPAIR OR ", :0
LEVEL REPLACE REPLACE 0
c:
,...to
m
en
OK INSPECT
.......
____O_K~INSPECT CHAnGE ~ INSPECT INLET :t
CHARGE
RELIEF VALVE FILTER 0
PUMP 0

DEFE~TIVE
I
CLOGGED
-
-f
2
f t C)

."
:0
REPAIR OR REPAIR OR 0
REPLACE
REPLACE REPLACE 0
m
., C
I C
"

,..--,-------. ::0
!m
REPLACE OJ' len
-
,. TRANSMISSION
(PUMP & MOTOR)
f-.E-_., INSPECT CHAnGE .....J._-------'
CHECK VALVES ~
I
I
I !

I
LOSS OF POWER OR SYSTEM Will
. ;:
',. NOT OPERATE IN EITHER DIRECTION
" " DEFECTIVE
I
 \

".. SECTION VII:

. MINOR REPAIR PROCEDtlRES

The following procedures cover the minor repairs for the 18 Series
hydrostatic "transmissions. Minor repairs are those that can be accomplished
without the removal of the end cap. These repairs can be performed,
following the procedures in this manual, without voiding the unit warranty .. :

.-.".
.... ....
..., ,.".... .
'"-- .'W"

.... - "
~--
~

:--
 I
SECTION VII: MINOR REPAIR PROCEDURES
_.",

C(
I

-)

I
I

PUMP MOTOR
VARIABLE DISPLACEMENT FIXED DISPLACEMENT

( C: Service Kits are available for repairing the arecs

noted. Consult Parts list for Model Number fe"
specific Service Kit and component pa;.
numbers.

AREA OF REPAIR

KIT DESCRIPTION

A Charge Pump·
B Charge Relief Valve
C Trunnio"nSeal
o I nput Shaft Seal
E By-Pass Valve .
F Output Shaft Seal
G Eharge Check Valves

MOTOR
VAR IABLE DISPLACEMENT

• Not 3wlicable to pumps with SAE Type AA. 2 &4 bolt.

auxiliary pump mounting pad.

16

.... - .
 -- --'---~'-'------'------~~.--- .

., ......
-~~
f:~ ;.~' ...
.

SECTION VII: MINOR 'REPAIR PROCEDURES . :: . '..- .f'!~....

.~~~ ~"~..'~'~:' ...:
...

.-..
. ....
~.

'. -

MOTOR
VARIABLE DISPLACEMENT

GENERAL PARTS IDENTIFICATION

NO. DESCRIPTION QTY

TRUNNION SEAL (C)

15 Seal-Lip 2

OUTPUT SHAFT SEAL (F)

22 Seal-Up 1
..
BY-PASS VALVE (G)
23 . By-Pass Valve Spool '. ',.' 1
.- 24 Back-Up Ring, " -..~( .. :. 1
25 . O-~ing '. 1
~ "., ';"':.: J: ,;?-::~'.-. '.

-.... ..... . ..
:.' '

MOTOR
FIXED DISPLACEMENT

, .
c
c

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