Cub Cadet P Series- Manuals

Page 4 - FOREWORD

P Series iv FOREWORD Headquartered in Sullivan, Illinois, Hydro-Gearis a world leader in the design, manufacture, andservice of quality hydrostatic transaxles for thelawn and garden industry. The mission of ourcompany is to be recognized by our customersand the industry as a world-class supplier and...

Page 6 - WarnInG; actuating the bypass will result in the; IntroductIon; SectIon 1. deScrIPtIon and oPeratIon

1 P Series In some applications of the P Series Pumps, it is desirable to move the machine for short distances at low speeds without operating the engine. A screw- type bypass valve is utilized in the pumps to permit movement of the machine. The bypass valve is fully opened when unscrewed two (2) tu...

Page 7 - eXternal FeatureS - Pc SerIeS; Figure 1. Pc Pump with Standard charge Pump

2 P Series eXternal FeatureS - Pc SerIeS Figure 1. Pc Pump with Standard charge Pump

Page 8 - Figure 2. PG Pump With Standard charge Pump; eXternal FeatureS - PG SerIeS

3 P Series Figure 2. PG Pump With Standard charge Pump eXternal FeatureS - PG SerIeS SAE “A” PAD FLANGE STYLE CHARGE PRESSURE DIAGNOSTIC PORT INPUT SHAFT INLET “A” and “B” PORTS STANDARD CHECK VALVE OR SCR CASE DRAIN OPTION BYPASS VALVE CHARGE COVER STANDARD CHECK VALVE OR SCR TRUNNION ARM CASE DRAI...

Page 9 - eXternal FeatureS - PJ SerIeS; Figure 3. PJ Pump with Standard charge Pump

4 P Series eXternal FeatureS - PJ SerIeS Figure 3. PJ Pump with Standard charge Pump

Page 10 - Figure 4. PK Pump With Standard charge Pump; eXternal FeatureS - PK SerIeS

5 P Series Figure 4. PK Pump With Standard charge Pump eXternal FeatureS - PK SerIeS

Page 11 - Figure 4. Pr Pump With Standard charge Pump; eXternal FeatureS - Pr SerIeS

6 P Series Figure 4. Pr Pump With Standard charge Pump eXternal FeatureS - Pr SerIeS TRUNNION ARM INPUT SHAFT CHARGE PRESSURE DIAGNOSTIC PORT “A” and “B” PORTS INLET BYPASS VALVE CASE DRAIN CHARGE COVER CASE DRAIN SYSTEM CHECK VALVE OR SHOCK VALVE SYSTEM CHECK VALVE OR SHOCK VALVE SAE “A” PAD FLANGE...

Page 12 - eXternal FeatureS - PW SerIeS; Figure 5. PW Pump With Standard charge Pump

7 P Series eXternal FeatureS - PW SerIeS Figure 5. PW Pump With Standard charge Pump CHARGE COVER STANDARD CHECK VALVE OR SHOCK VALVE STANDARD CHECK VALVE OR SHOCK VALVE SAE “B” PAD FLANGE STYLE TRUNNION ARM INPUT SHAFT BYPASS VALVE CASE DRAIN CHARGE PRESSURE DIAGNOSTIC PORT “A” and “B” PORTS

Page 13 - HydraulIc ScHematIc

8 P Series HydraulIc ScHematIc Figure 6. Pc, PG, PJ, PK and Pr Pumps with Standard charge Pump Orifice size No Bleed .024 Bleed .031 Bleed .044 Bleed Relief pressure (psi) Check ball 1740 2320 2900 Relief pressure (bar) Check ball 120 160 200 System Check & Relief Valve Options AUXILIARY DISCHAR...

Page 14 - Figure 8. PW Series Pump With Standard charge Pump

9 P Series HydraulIc ScHematIc Figure 8. PW Series Pump With Standard charge Pump Figure 9. PW Series Pump With auxiliary charge Pump Orifice size No Bleed .024 Bleed .031 Bleed .044 Bleed Relief pressure (psi) Check ball 1740 2320 2900 Relief pressure (bar) Check ball 120 160 200 System Check &...

Page 15 - Figure 10. P Series Pump With Standard charge Pump; GraPHIcal ScHematIc

10 P Series Figures 10 represents a graphical schematic of the P Series Pump with standard charge pump. Figure 10 provides a graphical illustration of the hydraulic oil circuit. The input shaft and pump cylinder block are turned in one direction only by the engine/drive belt/pulley combination or di...

Page 16 - tecHnIcal SPecIFIcatIonS; Table 1: P Series Pump Technical Specifications

11 P Series tecHnIcal SPecIFIcatIonS Table 1: P Series Pump Technical Specifications Product type Pc PG PJ/PK Pr PW displacement in 3 /rev 0.37 0.62 0.73 0.97 1.33 [cc/rev] [6.1] [10.2] [12] [16] [21.8] Input Speed Maximum Unloaded rpm 3600 3600 3600 3600 3600 Minimum Loaded rpm 1800 1800 1800 1800 ...

Page 17 - Figure 11. P Series Pump Configuration Label; Product IdentIFIcatIon; model number

12 P Series Figure 11. P Series Pump Configuration Label Product IdentIFIcatIon The label in Figure 11 is located on the pump housing. It identifies the model and configuration of the pump. HYDRO-GEAR MADE IN U.S.A. model number PC-AGCC-MV1X-XXXX 4 244 P1 0192 year Built date (Julian - day of year) ...

Page 19 - SectIon 3. trouBleSHootInG; do not attempt any servicing or ad-; valves, and loose or damaged control linkages. Be; table 2. Pump troubleshooting checklist; Possible cause

14 P Series SectIon 3. trouBleSHootInG WarnInG do not attempt any servicing or ad- justments with the engine running. use extreme caution while inspecting the drive belt assembly and all vehicle linkage!Follow all safety procedures outlined in the vehicle owner’s manual! In many cases, problems with...

Page 21 - P SerIeS FloW teSt KIt InStructIonS; pump or wheel motor system ports); InStallatIon and teStInG ProcedureS:

16 P Series P SerIeS FloW teSt KIt InStructIonS Bln-51334 July 2010 (This Instruction Sheet supersedes all previous flow testing instructions) description: P Series Flow test Kit (Part number 70661) (Part number 70661 Supersedes Part numbers 70511 and BB-76810) Purpose: The design purpose of the P S...

Page 22 - Pc

17 P Series note: Raising the system oil temperature will make a difference in the readings you receive. It has been determined that to complete this test accurately, the oil temperature must be near system operating temperatures. Suggested temperature range is 160°- 210°F (71.1° - 98.9°C). 8. On th...

Page 23 - SectIon 4. SerVIce and maIntenance; eXternal maIntenance; check the vehicle operator’s manual for

18 P Series SectIon 4. SerVIce and maIntenance note: any servicing dealer attempting a warranty repair must have prior approval before conducting maintenance of a Hydro-Gear product, unless the servicing dealer is a current authorized Hydro-Gear Service center. eXternal maIntenance Regular external ...

Page 24 - FluId Volume and leVel

19 P Series FluId Volume and leVel Certain situations may require additional fluid to be added or even replaced. Refer to the vehicle manufacturer’s recommendations for the proper fill location and level. After maintenance or oil change, follow purging procedures below and check the fluid level once...

Page 25 - return to neutral SettInG; The return to neutral mechanism on the pump is; Check for axle rotation. If the axle does not; Figure 17. P Series Pump rtn adjustment

20 P Series return to neutral SettInG WarnInG PotentIal For SerIouS InJury Inattention to proper safety, operation, or maintenance procedures could result in personal injury, or damage to the equip- ment. Before servicing or repairing the P Series Pump, fully read and understand the safety precautio...

Page 26 - HOW TO USE THIS MANUAL; REPAIR - PC SERIES PUMP

21 PC Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded views h o w i n g t h e p a r t s i n v o l v e d . T h e i t e mreference numbers in each illustration are forassembly instructions only. See pages 34 and 35f o r p a r t n a m e s a n d d e s c r i p t i o n s . Acomple...

Page 27 - Miscellaneous; P Series Service & Repair Manual; Combination Wrenches; Internal Snap Ring; Allen Wrenches; TOOLS AND TORQUES; Table 1. Required Tools; Torque

22 PC Series Miscellaneous 3/8-Inch Drive Ratchet and Sockets P Series Service & Repair Manual 7/16-inch Socket Torque Wrench 1/2-Inch Socket Scribe, Paint Pen, or Marker 11/16-Inch Socket Seal Hook with a Magnet 10-mm Socket Flat Blade Screwdriver Combination Wrenches Pliers 7/16 Inch Internal ...

Page 28 - Disassembly; PC SERIES PUMP REPAIR; Inspection; Figure 1. Return to Neutral Assembly

23 PC Series Refer to Figure 1. Prior to disassembly, note the position of the scissorarm brackets and the tab on the outer control armbracket. Disassembly CAUTION: The spring used on the return to neutrallinkage is under tension. To avoid possible injury,use care and proper protection during disass...

Page 29 - Install the fan and washer assembly onto the; Figure 2. Standard Control Arm; With the arm control linkage removed, inspect

24 PC Series REMOVAL, INSPECTION AND/ORREPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION AND/ORREPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. Disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on theshroud tabs. 2. Remove the nut (106) and fan assembly ...

Page 30 - Figure 4. PC Pump Input Shaft Seal

25 PC Series Refer to Figure 4. Disassembly 1. Remove retaining ring (22) from housing. 2. Remove lip seal (20). Care must be taken to prevent damage to the housing bore, shaftsealing surface, or bearing. Once removed, theseal is not reusable. Inspection With seal removed inspect the spacer (21) and...

Page 31 - Figure 6. PC Pump Shock Valves

26 PC Series Refer to Figure 6. Perform disassembly, inspection and assembly onshock valve one side at a time. Some units vary in“A” side to “B” side configuration. Disassembly 1. Remove the shock valve (42) with an 11/16-inch wrench. 2. Remove the shock valve spring and the shock valve from the end...

Page 32 - Figure 8. PC Pump Standard or Thru Shaft Charge Pump

27 PC Series Refer to Figure 8. Disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignmentat assembly. 2. Using a 1/2-inch wrench, loosen the charge pump cover bolts (10) from the end cap (2). Whileholding the charge cover (6) in place, removethe ch...

Page 33 - Figure 9. PC Series Auxiliary Pump

28 PC Series Refer to Figure 9. Disassembly 1. Prior to removal of the auxiliary pump, place a mark on the auxiliary pump (6), charge pump(7) and end cap (2) for alignment at assembly. 2. Use a 10 mm wrench to loosen the auxiliary pump bolts (10) from the end cap (2). Whileholding the auxiliary pump...

Page 34 - Using a 10 mm wrench, loosen the end cap bolts; or unusual wear patterns. Replace if necessary.; Assembly; Lubricate the mating surface of the cylinder; Figure 10. PC Pump End Cap

29 PC Series Refer to Figure 10. Disassembly 1. Remove charge pump. (See page 27). 2. Using a 10 mm wrench, loosen the end cap bolts (4) evenly. 3. Hold the end cap (2) in place and remove the four end cap bolts (4). 4. Slowly remove the end cap (2). 5. Remove housing gasket (5). Inspection 1. Inspe...

Page 35 - Figure 11. PC Pump Cylinder Block Assembly

30 PC Series Refer to Figure 11. Disassembly 1. Remove charge pump. (See page 27). 2. Remove end cap. (See page 29). 3. Tilt the pump on its side and drain remaining oil. Lift out the cylinder block assembly (25). 4. Remove the pistons, springs and piston seats. Inspection 1. Inspect the running sur...

Page 36 - Inspect the running surface of the bearing races; Figure 12. PC Pump Block Spring and; Inspect the running surface of the bearing pocket; Figure 13. PC Pump Swashplate and

31 PC Series Refer to Figure 12. Disassembly 1. Remove the block spring (29). 2. Remove the thrust bearing and races (34). Inspection 1. Inspect and replace the block spring (29) if it is distorted or broken. 2. Inspect the running surface of the bearing races for damage, nicks or unusual wear patte...

Page 37 - seal toward the outside of the pump.; Figure 14. PC Pump Input Shaft

32 PC Series Refer to Figure 14. Disassembly 1. Remove the retaining ring (22). 2. Remove the lip seal (20). 3. Remove the spacer (21). 3. Remove the shaft (18) and bearing (19) assembly (18) from the pump. Inspection 1. Inspect the input shaft (18) for worn splines, surface damage, or keyway damage...

Page 38 - Remove and discard the trunnion seal retainer; damage. Replace the trunnion arm if necessary.; To completely assemble the pump, refer to the; Figure 15. PC Pump Trunnion Arm

33 PC Series REMOVAL, INSPECTION ANDINSTALLATION OF TRUNNION ARM Refer to Figure 15. Disassembly 1. Remove the slot guide (38). 2. Remove and discard the trunnion seal retainer and seal (49). 3. Remove the trunnion arm (37). Inspection 1. Inspect the trunnion arm (37) for wear or damage. Replace the...

Page 39 - BOXES INDICATE ITEMS INCLUDED IN KITS.

34 PC Series Figure 16. PC Pump BOXES INDICATE ITEMS INCLUDED IN KITS. Kit Number

Page 40 - ITEM LIST - PC SERIES; Description

35 PC Series ITEM LIST - PC SERIES Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers. No. Description 1 Housing Kit 2 End Cap 4 Screw, Hex Flange, M8 x 1.25 5 Housing O-Ring 6 Charge Pump Kit (Std. Charge)Charge Pump Kit (Std. Charge) ThruShaft 7 STD Gerotor Assy (0.1...

Page 42 - The item; GENERAL INSTRUCTIONS; the appropriate kits identified in the Items Listing,; REPAIR - PG ANd PE SERIES PUMP; General Instructions

37 PG / PE Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See pages 52 and 53 for part names and descriptions. A complete exploded view and item list of the ...

Page 43 - TOOLS ANd TORQUES; 5, Aux Relief Valve Kit

38 PG / PE Series TOOLS ANd TORQUES Table 1. Required Tools Table 2. PG / PE Pump Torque Values Miscellaneous P Series Service & Repair ManualTorque WrenchScribe, Paint Pen, or MarkerSeal Hook with a MagnetFlat Blade Screwdriver Pliers Internal Snap Ring Allen Wrenches 5mm3/16 inch1/4 inch 3/8-I...

Page 44 - PG ANd PE SERIES PUMP REPAIR; REPLACEMENT OF RETURN TO; Prior to serial # 8001PXXXXX

39 PG / PE Series PG ANd PE SERIES PUMP REPAIR REMOVAL, INSPECTION ANd/OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY Figure 1. PG / PE Pump Return to Neutral Refer to Figure 1.Prior to disassembly, note the position of the scis- sor arm brackets and the tab on the outer control arm bracket. disassemb...

Page 45 - Install the fan and washer assembly onto the; Figure 2. PG / PE Pump Standard Control Arm; Install the inner control arm bracket, washer; Prior to serial # 8001PXXXX

40 PG / PE Series REMOVAL, INSPECTION ANd/OR REPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION ANd/OR REPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs. 2. Remove the nut (106) and fan a...

Page 46 - for corrosion and wear. Inspect the trunnion bore

41 PG / PE Series Refer to Figure 4. disassembly 1. Remove retaining ring (22) from housing. 2. Remove lip seal (20). Care must be taken to prevent damage to the housing bore, shaft sealing surface, or bearing. Once removed, the seal is not reusable. Inspection 1. With seal removed inspect the space...

Page 47 - REPLACEMENT OF CHECK VALVES; vary in “A” side to “B” side configuration.

42 PG / PE Series Refer to Figure 6. disassembly Perform disassembly, inspection and assembly on check valves one side at a time. Some units vary in “A” side to “B” side check configuration. 1. Remove the check valve (42) with an 1/4” allen wrench. 2. Remove the valve spring and poppet from the end ...

Page 48 - Inspect the bypass O-rings and mating seats; Lay the pump on its side, so the bypass port is; REPLACEMENT OF THE BYPASS

43 PG / PE Series Refer to Figure 8. disassembly 1. Loosen the bypass valve (15) using a 5/8” wrench. 2. Remove the bypass (15) from the end cap (2). Inspection 1. Inspect the bypass O-rings and mating seats in the end cap (2) for damage or foreign materials. 2. If damaged or worn replace bypass (15...

Page 49 - REMOVAL, INSPECTION ANd; Figure 9. PG / PE Pump Standard or Thru Shaft Charge Pump; semble the charge pump (6) until the

44 PG / PE Series Refer to Figure 9. disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignment at assembly. 2. Using a 1/2 inch wrench, or 5 mm allen wrench, loosen the charge pump cover bolts (10) from the end cap (2). While holding the charge cov...

Page 50 - disassembly; Use a 7/8 inch wrench to remove the filter cover; REPLACEMENT OF AUXILIARY; Inspect the filter cover assembly threads and; Install the poppet, spring and cap as one

45 PG / PE Series Refer to Figure 10. disassembly 1. Prior to removal of the auxiliary pump, place a mark on the auxiliary pump, charge pump (7) and end cap (2) for alignment at assembly. 2. Use a 10mm wrench to loosen the auxiliary pump bolts (10) from the end cap (2). While holding the auxiliary p...

Page 51 - Inspect the running surface (side that contacts; Install valve plate (31) so the stamped letters; Figure 11a. PG Pump End Cap

46 PG / PE Series Refer to Figure 11a and 11b. disassembly 1. Using a 10 mm wrench, loosen the end cap bolts (4) evenly. 2. Keeping the end cap (2) held in place, remove the four end cap bolts (4). 3. Slowly remove the end cap (2). 4. Remove the valve plate (31). NOTE: Not applicable in PE-series pu...

Page 53 - nesses: The thin race seats into the; Figure 13. PG / PE Pump Block Spring and Thrust; Inspect the running surface of the bearing pocket; NOTE: The cradle bearings will have; Cradle Bearings

48 PG / PE Series Refer to Figure 13. disassembly 1. Remove the block spring (29). 2. Remove the block thrust washer (30). 3. Remove the thrust bearing and race (34). Inspection 1. Inspect and replace the block spring (29) and thrust washer (30) if they are distorted or broken. 2. Inspect the runnin...

Page 54 - surface damage, or keyway damage. Replace; mallet may be necessary on the input shaft (18); delay reassembly of input shaft assem-

49 PG / PE Series REMOVAL, INSPECTION ANd ASSEMBLY OF INPUT SHAFT Refer to Figure 15. disassembly 1. Remove the retaining ring (22). 2. Remove the lip seal (20). 3. Remove the spacer (21). 4. Remove the shaft (18) from the pump. Inspection 1. Inspect the input shaft (18) for worn splines, surface da...

Page 55 - REMOVAL ANd INSPECTION OF; cate all seals, O-rings and gaskets with

50 PG / PE Series Refer to Figure 16. disassembly 1. Remove the slot guide (38). 2. Remove and discard the trunnion seal retainer and seal (49). 3. Remove the trunnion arm (37). Inspection 1. Inspect the trunnion arm (37) for wear or damage. Replace the trunnion arm if necessary. Assembly 1. Install...

Page 58 - ITEM LIST - PG ANd PE SERIES

53 PG / PE Series ITEM LIST - PG ANd PE SERIES Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers. No. description 1 Housing Kit 2 End Cap Kit (W/Poppets, Standard Charge) End Cap Kit (W/ SCR’S, Standard Charge) End Cap Kit (W/ Poppets, Auxiliary Charge) End Cap Kit (W...

Page 60 - T h e i t e m; REPAIR - PJ SERIES PUMP

55 PJ Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded views h o w i n g t h e p a r t s i n v o l v e d . T h e i t e m reference numbers in each illustration are forassembly instructions only. See pages 70 and 71 for part names and descriptions. A completeexploded view and ...

Page 61 - Pliers

56 PJ Series TOOLS AND TORQUES Table 1. Required Tools Table 2. PJ Pump Torque Values Miscellaneous P Series Service & Repair Manual Torque Wrench Scribe, Paint Pen, or Marker Seal Hook with a Magnet Flat Blade Screwdriver Pliers Internal Snap Ring Allen Wrenches 5mm 1/8 inch 3/16 inch 1/4 inch ...

Page 62 - PJ SERIES PUMP REPAIR; Figure 1. PJ Pump Return to Neutral; The spring used on the return to neutral; bracket must move freely.

57 PJ Series PJ SERIES PUMP REPAIR REMOVAL, INSPECTION AND/ORREPLACEMENT OF RETURN TONEUTRAL ASSEMBLY Figure 1. PJ Pump Return to Neutral Refer to Figure 1. Prior to disassembly, note the position of the scissorarm brackets and the tab on the outer control armbracket. Disassembly CAUTION: The spring...

Page 63 - Figure 2. PJ Pump Standard Control Arm

58 PJ Series REMOVAL, INSPECTION AND/ORREPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION AND/ORREPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. Disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on theshroud tabs. 2. Remove the nut (106) and fan assembly ...

Page 64 - Figure 4. PJ Pump Input Shaft Seal

59 PJ Series Refer to Figure 4. Disassembly 1. Remove retaining ring (22) from housing. 2. Remove lip seal (20). Care must be taken to prevent damage to the housing bore, shaftsealing surface, or bearing. Once removed, theseal is not reusable. Inspection With seal removed inspect the spacer (21) and...

Page 65 - Figure 6. PJ Pump Check Valves

60 PJ Series Refer to Figure 6. Perform disassembly, inspection and assembly oncheck valves one side at a time. Some units vary in“A” side to “B” side check configuration. Disassembly 1. Remove the check valve (42) with an 1/4” allen wrench. 2. Remove the valve spring and poppet from the end cap. In...

Page 66 - Inspect the bypass O-rings and mating seats in; Lay the pump on its side, so the bypass port is; Figure 8. PJ Pump Bypass

61 PJ Series Refer to Figure 8. Disassembly 1. Loosen the bypass valve (15) using a 5/8” wrench. 2. Remove the bypass (15) from the end cap (2). Inspection 1. Inspect the bypass O-rings and mating seats in the end cap (2) for damage or foreign materials. 2. If damaged or worn replace bypass (15) Ass...

Page 67 - Figure 9. PJ Pump Standard or Thru Shaft Charge Pump

62 PJ Series Refer to Figure 9. Disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignmentat assembly. 2. Using a 1/2 inch wrench, or 5 mm allen wrench, loosen the charge pump cover bolts (10) fromthe end cap (2). While holding the charge coverin pl...

Page 68 - Figure 10. Auxiliary Pump

63 PJ Series Refer to Figure 10. Disassembly 1. Prior to removal of the auxiliary pump, place a mark on the auxiliary pump, charge pump (7)and end cap (2) for alignment at assembly. 2. Use a 10mm wrench to loosen the auxiliary pump bolts (10) from the end cap (2). Whileholding the auxiliary pump in ...

Page 69 - mating surface with clean oil prior to installation.; Figure 11. PJ Pump End Cap

64 PJ Series Refer to Figure 11. Disassembly 1. Remove charge pump. (See page 62). 2. Using a 10 mm wrench, loosen the end cap bolts (4) evenly. 3. Hold the end cap (2) in place and remove the four end cap bolts (4). 4. Slowly remove the end cap (2). 5. Remove housing gasket (5). Inspection 1. Inspe...

Page 70 - Figure 12. PJ Pump Cylinder Block

65 PJ Series Refer to Figure 12. Disassembly 1. Remove charge pump. (See page 62). 2. Remove end cap. (See page 64). 3. Tilt the pump on its side and drain remaining oil. Lift out the cylinder block assembly (25). 4. Remove the pistons, springs and piston seats. Inspection 1. Inspect the running sur...

Page 71 - Inspect the running surface of the bearing races; Figure 13. Pump Block Spring and Thrust Bearing; Figure 14. PJ Pump Swashplate and Cradle; swashplate moves freely.

66 PJ Series 1. Install thrust bearing and race assembly (34). 2. Install the block thrust washer (30). 3. Install block spring (29). Refer to Figure 13. Disassembly 1. Remove the block spring (29). 2. Remove the block thrust washer (30) and thrust bearing (34). Inspection 1. Inspect and replace the...

Page 72 - assembly from the pump.; Figure 15. PJ Pump Input Shaft

67 PJ Series REMOVAL, INSPECTION ANDASSEMBLY OF INPUT SHAFT Refer to Figure 15. Disassembly 1. Remove the retaining ring (22). 2. Remove the lip seal (20). 3. Remove the spacer (21). 4. R e m o v e t h e s h a f t ( 1 8 ) a n d b e a r i n g ( 1 9 ) assembly from the pump. Inspection 1. Inspect the ...

Page 73 - Figure 16. PJ Pump Trunnion Arm; To completely assembly the pump, refer to the

68 PJ Series Refer to Figure 16. Disassembly 1. Remove the slot guide (38). 2. Remove and discard the trunnion seal retainer and seal (49). 3. Remove the trunnion arm (37). Inspection REMOVAL, INSPECTION ANDINSTALLATION OF TRUNNION ARM Figure 16. PJ Pump Trunnion Arm 1. Inspect the trunnion arm (37)...

Page 75 - BOXES INDICA

70 PJ Series Figure 17. PJ Pump BOXES INDICA TE ITEMS INCLUDED IN KITS. Kit Number

Page 76 - ITEM LIST - PJ SERIES

71 PJ Series ITEM LIST - PJ SERIES Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers. No. Description 1 Housing Kit 2 End Cap Kit (W/Poppets, Standard Charge)End Cap Kit (W/ SCR’S, Standard Charge)End Cap Kit (W/ Poppets, Auxiliary Charge)End Cap Kit (W/ SCR’S, Auxili...

Page 78 - REPAIR - PK SERIES PUMP

73 PK Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded views h o w i n g t h e p a r t s i n v o l v e d . T h e i t e m reference numbers in each illustration are forassembly instructions only. See pages 88 and 89 for part names and descriptions. A completeexploded view and ...

Page 80 - PK SERIES PUMP REPAIR; Figure 1. PK Pump Return to Neutral

75 PK Series Refer to Figure 1. Prior to disassembly, note the position of the scissorarm brackets and the tab on the outer control armbracket. Disassembly CAUTION: The spring used on the return to neutral linkage is under tension. To avoid possible injury,use care and proper protection during disas...

Page 81 - Figure 2. PK Pump Standard Control Arm

76 PK Series REMOVAL, INSPECTION AND/ORREPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION AND/ORREPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. Disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on theshroud tabs. 2. Remove the nut (106) and fan assembly ...

Page 82 - Figure 4. PK Pump Input Shaft Seal

77 PK Series Refer to Figure 4. Disassembly 1. Remove retaining ring (22) from housing. 2. Remove lip seal (20). Care must be taken to prevent damage to the housing bore, shaftsealing surface, or bearing. Once removed, theseal is not reusable. Inspection With seal removed inspect the spacer (21) and...

Page 83 - Figure 6. PK Pump Check Valves

78 PK Series Refer to Figure 6. Perform disassembly, inspection and assembly oncheck valves one side at a time. Some units vary in“A” side to “B” side check configuration. Disassembly 1. Remove the check valve (42) with an 1/4” allen wrench. 2. Remove the valve spring and poppet from the end cap. In...

Page 84 - Figure 8. PK Pump Bypass

79 PK Series Refer to Figure 8. Disassembly 1. Loosen the bypass valve (15) using a 5/8” wrench. 2. Remove the bypass (15) from the end cap (2). Inspection 1. Inspect the bypass O-rings and mating seats in the end cap (2) for damage or foreign materials. 2. If damaged or worn replace bypass (15) Ass...

Page 85 - Figure 9. PK Pump Standard or Thru Shaft Charge Pump

80 PK Series Refer to Figure 9. Disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignmentat assembly. 2. Using a 1/2 inch wrench, or 5 mm allen wrench, loosen the charge pump cover bolts (10) fromthe end cap (2). While holding the charge coverin pl...

Page 87 - Figure 11. PK Pump End Cap

82 PK Series Refer to Figure 11. Disassembly 1. Remove charge pump. (See page 62). 2. Using a 10 mm wrench, loosen the end cap bolts (4) evenly. 3. Hold the end cap (2) in place and remove the four end cap bolts (4). 4. Slowly remove the end cap (2). 5. Remove housing gasket (5). Inspection 1. Inspe...

Page 88 - Figure 12. PK Pump Cylinder Block

83 PK Series Refer to Figure 12. Disassembly 1. Remove charge pump. (See page 80. 2. Remove end cap. (See page 82). 3. Tilt the pump on its side and drain remaining oil. Lift out the cylinder block assembly (25). 4. Remove the pistons, springs and piston seats. Inspection 1. Inspect the running surf...

Page 89 - Figure 14. PK Pump Swashplate and Cradle

84 PK Series 1. Install thrust bearing and race assembly (34). 2. Install the block thrust washer (30). 3. Install block spring (29). Refer to Figure 13. Disassembly 1. Remove the block spring (29). 2. Remove the block thrust washer (30) and thrust bearing (34). Inspection 1. Inspect and replace the...

Page 90 - Figure 15. PK Pump Input Shaft

85 PK Series REMOVAL, INSPECTION ANDASSEMBLY OF INPUT SHAFT Refer to Figure 15. Disassembly 1. Remove the retaining ring (22). 2. Remove the lip seal (20). 3. Remove the spacer (21). 4. R e m o v e t h e s h a f t ( 1 8 ) a n d b e a r i n g ( 1 9 ) assembly from the pump. Inspection 1. Inspect the ...

Page 91 - Figure 16. PK Pump Trunnion Arm

86 PK Series Refer to Figure 16. Disassembly 1. Remove the slot guide (38). 2. Remove and discard the trunnion seal retainer and seal (49). 3. Remove the trunnion arm (37). Inspection REMOVAL, INSPECTION ANDINSTALLATION OF TRUNNION ARM Figure 16. PK Pump Trunnion Arm 1. Inspect the trunnion arm (37)...

Page 94 - ITEM LIST - PK SERIES

89 PK Series ITEM LIST - PK SERIES Part numbers are not provided in this manual. See website for part numbers. No. Description 1 Housing Kit 2 End Cap Kit (W/Poppets, Standard Charge)End Cap Kit (W/ SCR’S, Standard Charge)End Cap Kit (W/ Poppets, Auxiliary Charge)End Cap Kit (W/ SCR’S, Auxiliary Cha...

Page 96 - REPAIR - PR SERIES PUMP

91 PR Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See pages 106 and 107 for part names and descriptions. A complete exploded view and item list of the pum...

Page 98 - PR SERIES PUMP REPAIR; Install the inner scissor control arm bracket; Figure 1. PR Pump Return to Neutral

93 PR Series Prior to disassembly, note the position of the scis- sor arm brackets and the tab on the outer control arm bracket.See Figure 1. DisassemblyCAUTION: The spring used on the return to neutral linkage is under tension. To avoid possible injury, use care and proper protection during disasse...

Page 99 - REPLACEMENT OF CONTROL ARM; Figure 2. PR Pump Standard Control Arm

94 PR Series REMOVAL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. Disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs. 2. Remove the fan nut and fan assembly...

Page 100 - REPLACEMENT OF INPUT SHAFT; Figure 4. PR Pump Input Shaft Seal; REPLACEMENT OF TRUNNION; Figure 5. PR Pump Trunnion Arm Seal

95 PR Series Refer to Figure 4. Disassembly 1. Remove retaining ring (3) from housing (15). 2. Remove lip seal (6). Care must be taken to prevent damage to the housing bore, shaft sealing surface, or bearing. Once removed, the seal is not reusable. Inspection 1. With the lip seal (6) removed, inspec...

Page 101 - in “A” side to “B” side check configuration.; Figure 6. PR Pump Check Valves

96 PR Series Refer to Figure 6. Disassembly Perform disassembly, inspection and assembly on check valves one side at a time. Some units vary in “A” side to “B” side check configuration. 1. Remove the check valve (42) with an 1/4” allen wrench. 2. Remove the valve spring and poppet from the end cap (...

Page 102 - Figure 8. PR Pump Bypass

97 PR Series Refer to Figure 8. Disassembly 1. Loosen the bypass valve (50) using a 5/8” wrench. 2. Remove the bypass (50) from the end cap (25). Inspection 1. Inspect the bypass O-rings and mating seats in the end cap (25) for damage or foreign materials. 2. If damaged or worn replace bypass (50). ...

Page 103 - REMOVAL, INSPECTION AND; Figure 9. PR Pump Standard or Thru Shaft Charge Pump; end cap is installed on the housing.

98 PR Series Refer to Figure 9. Disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignment at assembly. 2. Using a 1/2 inch wrench loosen the charge pump cover bolts (56) from the end cap (2). While holding the charge cover in place, remove the char...

Page 104 - Figure 10. PR Series Auxiliary Pump

99 PR Series Refer to Figure 10. Disassembly 1. Prior to removal of the auxiliary pump, place a mark on the auxiliary pump, charge pump (41) and end cap (25) for alignment at assembly. 2. Use a 10mm wrench to loosen the auxiliary pump bolts (56) from the end cap (25). While holding the auxiliary pum...

Page 105 - Install valve plate (29) so the bronze side of the; Figure 11. PR Pump End Cap; Prior to Serial # 0216Pxxxxx

100 PR Series Refer to Figure 11. Disassembly 1. Using any combination of two, 9/16” wrenches or 9/16” socket and ratchet drive, loosen the end cap bolts (58) evenly. 2. Keeping the end cap (25) held in place, remove the four end cap bolts (58). 3. Slowly remove the end cap (25). 4. Remove the valve...

Page 106 - Figure 12. PR Pump Cylinder Block

101 PR Series Refer to Figure 12. Disassembly 1. Tilt the pump on its side, drain remaining oil. Lift out the cylinder block assembly (38). 2. Remove the pistons, springs and piston seats. Inspection 1. Inspect the running surface of the cylinder block and piston ends for damage, nicks or unusual we...

Page 107 - Inspect the running surface of the bearing race; Figure 13. PR Pump Block Spring and; Figure 14. PR Pump Swashplate and; plate. The thicker race will be installed

102 PR Series Refer to Figure 13. Disassembly 1. Remove the block spring (20). 2. Remove the thrust washer (19). 3. Remove the thrust bearing and race (17). Inspection 1. Inspect and replace the block spring (20) and thrust washer (19) if they are distorted or broken. 2. Inspect the running surface ...

Page 108 - Figure 15. PR Pump Input Shaft

103 PR Series REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT Refer to Figure 15. Disassembly 1. Remove the retaining ring (3). 2. Remove the lip seal (6). 3. Remove the spacer (4). 4. Remove the shaft assembly (1). Inspection 1. Inspect the input shaft (1) for worn splines, damage, or keyway damage...

Page 109 - REMOVAL AND INSPECTION OF; Figure 16. PR Pump Trunnion Arm

104 PR Series Refer to Figure 16. Disassembly 1. Remove and discard the trunnion seal retainer and seal (12). 2. Remove the slot guide (14). 3. Remove the trunnion arm (13). Inspection 1. Inspect the trunnion arm (13) for wear or damage. Replace the trunnion arm if necessary. Assembly 1. Install the...

Page 112 - ITEM LIST - PR SERIES; No. Description; 04 Inner Scissor Arm

107 PR Series ITEM LIST - PR SERIES Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers. 1 Pump Shaft Kit (19T spline) Pump Shaft Kit (17 mm keyed) Pump Shaft Kit (17 mm keyed thru taper) Pump Shaft Kit (double tapered thru shaft) 3 Retaining Ring 4 Spacer 5 Shaft Ball ...

Page 114 - REPAIR - PW SERIES PUMP

109 PW Series HOW TO USE THIS MANUAL Each assembly is provided with an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See pages 124 and 125 for part names and descriptions. A complete exploded view and item list of the pu...

Page 115 - 4, Charge Relief Kit

110 PW Series TOOLS AND TORQUES Table 1. Required Tools Table 2. PW Pump Torque Values Miscellaneous P Series Service & Repair ManualTorque WrenchScribe, Paint Pen, or MarkerSeal Hook with a MagnetFlat Blade Screwdriver Pliers Internal Snap Ring Allen Wrenches 5mm3/16 inch1/4 inch 3/8-Inch Drive...

Page 116 - PW SERIES PUMP REPAIR; Figure 1. PW Pump Return to Neutral

111 PW Series Prior to disassembly, note the position of the scis- sor arm brackets and the tab on the outer control arm bracket.See Figure 1. DisassemblyCAUTION: The spring used on the return to neutral linkage is under tension. To avoid possible injury, use care and proper protection during disass...

Page 117 - Figure 2. PW Pump Standard Control Arm

112 PW Series REMOVAL, INSPECTION AND/OR REPLACEMENT OF CONTROL ARM REMOVAL, INSPECTION AND/OR REPLACEMENT OF FAN ASSEMBLY Refer to Figure 3. Disassembly 1. Remove the fan shroud (210) from the mounting bracket (209) by carefully pushing down on the shroud tabs. 2. Remove the fan nut and fan assembl...

Page 118 - Figure 4. PW Pump Input Shaft Seal; Figure 5. PW Pump Trunnion Arm Seal

113 PW Series Refer to Figure 4. Disassembly 1. Remove retaining ring (3) from housing (15). 2. Remove lip seal (6). Care must be taken to prevent damage to the housing bore, shaft, sealing surface, or bearing. Once removed, the seal is not reusable. Inspection 1. With the lip seal (6) removed, insp...

Page 119 - Figure 6. PW Pump Check Valves

114 PW Series Refer to Figure 6. Disassembly Perform disassembly, inspection and assembly on check valves one side at a time. Some units vary in “A” side to “B” side check configuration. 1. Remove the check valve (42) with an 1/4” allen wrench. 2. Remove the valve spring and poppet from the end cap ...

Page 120 - Figure 8. PW Pump Bypass

115 PW Series Refer to Figure 8. Disassembly 1. Loosen the bypass valve (50) using a 5/8” wrench. 2. Remove the bypass (50) from the end cap (25). Inspection 1. Inspect the bypass O-rings and mating seats in the end cap (25) for damage or foreign materials. 2. If damaged or worn replace bypass (50) ...

Page 121 - Figure 9. PW Pump Standard or Thru Shaft Charge Pump

116 PW Series Refer to Figure 9. Disassembly 1. Prior to removal of the charge pump cover, place a mark on the cover and end cap for alignment at assembly. 2. Using a 1/2 inch wrench loosen the charge pump cover bolts (56) from the end cap (25). While holding the charge cover in place, remove the ch...

Page 122 - Figure 10. PW Series Auxiliary Pump

117 PW Series Refer to Figure 10. Disassembly 1. Prior to removal of the auxiliary pump, place a mark on the auxiliary pump, charge pump (41) and end cap (25) for alignment at assembly. 2. Use a 10mm wrench to loosen the auxiliary pump bolts (56) from the end cap (25). While holding the auxiliary pu...

Page 123 - checked by dragging a fingernail across the; Install valve plate (29) with the bronze side; Figure 11. PW Pump End Cap

118 PW Series Refer to Figure 11. Disassembly 1. Using any combination of two, 9/16” wrenches or 9/16” socket and rachet drive, loosen the end cap bolts (58) evenly. 2. Keeping the end cap (25) held in place, remove the four end cap bolts (58). 3. Slowly remove the end cap (25). 4. Remove the valve ...

Page 124 - Figure 12. PW Pump Cylinder Block

119 PW Series Refer to Figure 12. Disassembly 1. Tilt the pump on its side, drain remaining oil. Lift out the cylinder block assembly (38). 2. Remove the pistons, springs and piston seats. Inspection 1. Inspect the running surface of the cylinder block and piston ends for damage, nicks or unusual we...

Page 125 - Inspect the running surface of the bearing race; Figure 13. PW Pump Thrust Bearing; Figure 14. PW Pump Swashplate and

120 PW Series Refer to Figure 13. Disassembly 1. Remove the thrust bearing and race (17). Inspection 1. Inspect the running surface of the bearing race for damage (17), nicks or unusual wear patterns. The running surface may show evidence of minor abrasion. This will be normal wear. Inspect the bear...

Page 126 - Figure 15. PW Pump Input Shaft

121 PW Series REMOVAL, INSPECTION AND ASSEMBLY OF INPUT SHAFT Refer to Figure 15. Disassembly 1. Remove the retaining ring (3). 2. Remove the lip seal (6). 3. Remove the spacer (4). 4. Remove the shaft assembly (1). Inspection 1. Inspect the input shaft (1) for worn splines, damage, or keyway damage...

Page 127 - Install a new seal and seal retainer.; Figure 16. PW Pump Trunnion Arm

122 PW Series Refer to Figure 16. Disassembly 1. Remove trunnion seal retainer and seal (12). 2. Remove the slot guide (14). 3. Remove the trunnion arm (13). Inspection 1. Inspect the trunnion arm (13) for wear or damage. Replace the trunnion arm if necessary. Assembly 1. Install the trunnion arm (1...

Page 130 - ITEM LIST - PW SERIES; No. Description

125 PW Series ITEM LIST - PW SERIES Part numbers are not provided in this manual. See CD (BLN-51427) for part numbers. 1 Pump Shaft Kit (19T spline) Pump Shaft Kit (closed key) Pump Shaft Kit (thru shaft spline) Pump Shaft Kit (tapered thru shaft) Pump Shaft Kit (shaft - thru pump) Retaining Ring 4 ...

Page 132 - GLOSSARY OF TERMS; Decay Rate: The ratio of pressure decay over time.

127 P Series GLOSSARY OF TERMS Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arrangedparallel with the spindle (input or output shaft). Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motoror pump. Also referred to occ...

Page 133 - Manifold: A conductor which provides multiple connection ports.

128 P Series Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing toform a device for the control and transfer of power. Inlet Line: A supply line to the pump. Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission andgear case in one ...