Text preview for : Chapter_10_Hydrostatic_Drive.pdf part of Polaris Brutus HDPTO Polaris Brutus, Brutus HD, and Brutus HD PTO Service Manual Hydrostatic Drive
Chapter 10: Hydrostatic Drive
(Also Covers Bobcat 3600 and Bobcat 3650)
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HYDROSTATIC DRIVE
CHAPTER 10 HYDROSTATIC DRIVE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 LUBRICATION SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 HYDROSTATIC DRIVE MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 DRIVE RELIEF PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 COUPLER REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 HYDROSTATIC PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 HYDROSTATIC PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
HYDROSTATIC TRAVEL CONTROL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 10.34 NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 TRAVEL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 FORWARD SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 10.37 REVERSE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 10.38 ENGINE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
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CHARGE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
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HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
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10.1
TRAVEL CONTROL (TREADLE) PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
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TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
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DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
HYDROSTATIC DRIVE
GENERAL INFORMATION
Torque Specifications
ITEM Hydrostatic Drive Motor Mounting Bolts Drive Motor Poppet Valve Plug Drive Motor Centering Spring Plug Hydrostatic Pump Coupler Bolt Hydrostatic Pump End Cap Plug Hydrostatic Pump Relief Valve Plug TORQUE VALUE 100 ft-lbs (136 Nm) 20 ft-lbs (27 Nm) 27 ft-lbs (37 Nm) 40 ft-lbs (54 Nm) 20 ft-lbs (27 Nm) 20 ft-lbs (27 Nm)
HYDROSTATIC SYSTEM INFORMATION
Description WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and decals on the machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.
Special Tools
PART NUMBER PU-51261 PU-51219 PU-51199 PU-51022 PU-51022-1 TOOL DESCRIPTION Drive Control Adjustment Wrench Hydraulic Adapter Kit Quick Coupler Kit Quadrigage Coupler Kit
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Recommended Hydraulic Lubricant: Polaris Hydraulic Fluid (PN 2879746) (Gallon)
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Reservoir Capacity: All Models: 2.75 qts (2.6 L) Full System Capacity: BRUTUS: 7.2 qts. (6.8 L)
BRUTUS HD / HDPTO: 8.4 qts (7.9 L)
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Lubrication Specification
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The hydrostatic pump is connected to the engine by a coupler and provides fluid to the hydrostatic drive motor. The charge pressure system assists in replenishing the fluid that is lost due to internal leakage in the components of the hydrostatic system.
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The hydrostatic system consists of a hydrostatic pump and hydrostatic drive motor that allows forward and reverse motion in the vehicle.
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HYDROSTATIC DRIVE
HYDROSTATIC DRIVE MOTOR
Description
Mounted to the transmission input shaft, the hydrostatic drive motor is powered by the hydrostatic pump. A shuttle valve located inside the end cap of the hydrostatic drive motor helps to keep the motor cool by mixing case drain oil with cooled low pressure oil from the charge circuit. The shuttle valve is shifted by the high pressure oil coming from the hydrostatic pumps. 2. Loosen the intake hose clamps (Item 1).
1
Removal / Installation WARNING
To avoid serious injury or death, clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire IMPORTANT: When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system 1. For installation, reverse this procedure.
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1 3. Remove the bolts (Item 2) and remove the air intake.
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10.3
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HYDROSTATIC DRIVE
4. Mark and remove the hoses (Item 3) from the top of the drive motor.
3
3
5. Remove the drive motor bottom bolt (Item 4).
4
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6. Remove the top bolt (Item 5) and drive motor (Item 6).
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10.4
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Hydrostatic Drive Motor Exploded View
1. SNAP RING 2. WASHER 3. SEAL 4. BEARING 5. HOUSING 6. O-RING 7. PLUG 8. SHAFT 9. BEARING 10. SWASH PLATE 11. ROTARY GROUP ASSY 12. VALVE PLATE 13. GASKET 14. PIN 15. GUIDE PIN 16. POPPET 7 17. SPRING 18. SPRING STOP 19. SPOOL 20. BOLT 21. VALVE BODY 22. PISTON 23. ANGLE STOP 6 23
17 22 3 6
21 6 7 18
17 15 14
6 20 15 19 6 17 18 1
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Disassembly
IMPORTANT: When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system 1. Remove the snap ring (Item 1). 3. Remove the snap ring (Item 4) and remove the output shaft (Item 5).
4
2
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4. If the bearing or shaft needs replacement, remove the bearing (Item 6) from the shaft.
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2. Remove the seal (Item 3).
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5. Remove bolts (Item 7) end cap (Item 8).
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HYDROSTATIC DRIVE
6. Remove the valve plate (Item 9) and the angle stop (Item 10). 9. Remove the plug (Item 14) and centering spring (Item 15).
10
9
7. Remove the plugs (Item 11) and remove the o-rings from the plugs.
11
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17 18
10. Remove the plug (Item 16) and centering spring (Item 17). Remove the o-ring from the plug.
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15 14 16
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11. Remove the poppet (Item 18). 8. Remove the plug (Item 12) and centering spring (Item 13). Remove the o-ring from the plug.
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HYDROSTATIC DRIVE
12. Remove the shift spool (Item 19). NOTE: The following procedure shown is to disassemble the rotating group for inspection only. The rotating group parts can not be ordered separately and must be ordered as an assembly. 15. Inspect the pistons for scoring and scratches. Verify the holes (Item 23) in the slippers are not plugged.
19
13. Remove the spring (Item 20) and the cylinder block (Item 21).
16. Inspect the mating surface of the retaining ring (Item 24) for scoring and scratches. 20
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14. Remove the piston assembly (Item 22) and retainer ball from the cylinder block.
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17. Remove the swash plate (Item 25).
Drive Motor Assembly
1. Clean all parts in solvent and dry with compressed air. Replace all o-rings and seals. Inspect all parts for wear or damage. Replace any worn or damaged parts. 2. Install the seal (Item 1).
25
18. Remove the bearings (Item 26).
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27
3. Install the bearings (Item 2) and servo piston (Item 3).
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26
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19. Remove the servo piston (Item 27).
10
20. Remove the seal (Item 28) from the servo piston.
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4. Install the swash plate (Item 4). 7. Install the cylinder block (Item 7) into the motor housing.
4
5. Install the retainer ball (Item 5) on the cylinder block.
8. Install the spring (Item 8) into the motor housing.
5
6. Install the piston assembly (Item 6).
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6 9
9. Install the shift spool (Item 9) into the end cap.
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10. Install the poppet (Item 10) into the end cap. 12. Install a new o-ring on the plug (Item 13) and install the centering spring (Item 14) and plug into the end cap. (Both sides) Torque the plug to specification.
10
11. Install a new o-ring on the plug (Item 12) and install the centering spring (Item 11) and plug into the end cap. Torque the plug to specification.
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Centering Spring Plug: 27 ft-lbs (37 Nm)
11
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13. Install the o-ring (Item 15) on the plugs.
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Poppet Valve Plug: 20 ft-lbs (27 Nm)
10.11
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HYDROSTATIC DRIVE
14. Install the plugs (Item 16) into the back of the end cap. 18. Install the output shaft (Item 20) into the motor housing.
16
15. Install the angle stop (Item 17) into the end cap.
19. Install the snap ring (Item 21).
17
16. Install the end cap (Item 18) and bolts (Item 19).
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19 18 17. If Removed, press a new bearing onto the shaft.
20. Install the seal (Item 22).
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10.12
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HYDROSTATIC DRIVE
21. Install the washer (Item 23) and snap ring Item 24).
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HYDROSTATIC DRIVE
CHARGE PRESSURE
Description
Charge pressure is a supply of oil feeding the hydrostatic pump. Charge pressure is regulated by a charge relief valve located inside the hydrostatic pump. Charge pressure is used to replenish hydrostatic fluid removed from the drive circuit, pump and motor "Internal leakage", and from the hydrostatic drive motors shuttle "flushing" valve. Charge pressure is also used to operate other hydraulic functions, such as shifting the auxiliary spool in the priority valve. The charge pressure is tested at the outlet side of the hydraulic filter. 3 adapter (PU-51199) (Item 3).
4. Install the quadrigage (PU-51022) (Item 4).
Testing
1. Lift and block the machine. 2. Remove the hose (Item 1) from the hydraulic filter outlet (Item 2).
2
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5. Start the engine. The gauges should read as follows: 87 PSI (0,6 MPa) with approximately 140°F (53°C) fluid @ High Idle.
3. Install a hydraulic adapter fitting (PU-51219) with test
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The charge pressure relief valve is not adjustable and must be replaced if desired pressures cannot be obtained.
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HYDROSTATIC DRIVE
HYDROSTATIC PUMP
Description
Bolted on the engine just off the crankshaft, the hydrostatic pump is composed of a single (piston) pump. The pump provides flow to the drive motor. The pump contains replenishing valves that provide fluid to the low pressure side of the hydrostatic circuit. The replenishing valve also keeps high pressure fluid out of the low pressure side of the hydrostatic circuit. 5. Start the engine and place the shift lever in high. 6. Use the travel control pedal to obtain high idle. The gauge should read 5004 PSI (34501 kPa).
Hydrostatic Pump Removal / Installation WARNING
Drive Relief Pressure Testing
1. Raise the vehicle so all four wheels are off the ground and place on jack stands. 2. Remove the hose (Item 1) from port B on the drive motor.
1
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IMPORTANT: When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always cap / plug the hoses, tubelines and ports to keep dirt out. 1. For installation, reverse this procedure. 2. Remove the hose clamps (Item 1) for the intake.
NOTE: Port B on the drive motor is the forward port and port A is the reverse port. 3. Install an adapter (PU-51199) (Item quadrigage (PU-51022) on the hose.
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1 1
To avoid serious injury or death, clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.
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10
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3
2)
and
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2 4. Install a cap (Pu-51219) (Item 3) on the drive motor.
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HYDROSTATIC DRIVE
3. Remove the bolts (Item 2) and air duct (Item 3). 6. Loosen the bolts (Item 6) and remove the cover (Item 7) from the top of the pump.
6 2 2 7
4. Disconnect the neutral safety switch connector (Item 4) from the main harness.
7. Cut and remove the tie strap (Item 8) from the engine speed control cables.
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5. Loosen the bolt (Item 5) from the front of the cover. 8. Loosen the jam nuts (Item 9) on the forward speed control cable.
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HYDROSTATIC DRIVE
9. Remove the cable end (Item 10) from the pump plate. 12. Remove the C clip (Item 13) and washer (Item 14) from the travel control cable end.
13
10. Loosen the jam nuts (Item 11) on the reverse speed control cable.
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13. Loosen the travel control cable jam nuts (Item 15) and remove the cable from the pump plate.
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14 15 15 16
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14. Remove the centering springs (Item 16).
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11. Remove the cable end (Item 12) from the pump plate.
17
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15. Loosen the HP spring bolt (Item 17) until spring pressure has been released.
10.17
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HYDROSTATIC DRIVE
16. Remove the bolt (Item 18) and washer (Item 19). 20. Remove the snap ring (Item 24).
19
17. Remove the bushing (Item 20).
21. Remove the washer (Item 25). 22. Remove the plastic washer (Item 26).
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18. Remove the command lever (Item 21) and HP spring (Item 22). 19. Remove the washer (Item 23).
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23. Remove the top centering plate (Item 27).
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24. Remove bottom centering plate (Item 28).
10.18
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26 27 28
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HYDROSTATIC DRIVE
25. Remove the plastic washer (Item 29). 28. Remove the four bolts (Item 32) and pump plate. 32
30
29
31
29. Mark and remove the hoses (Item 33). 26. Loosen the bolt (Item 30) and remove the pintle lever (Item 31). 27. Mark the position of the pump plate with reference to the bell housing for ease of installation.
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33 30. Remove the bolts (Item 34) and the hydrostatic pump (Item 35).
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34 35
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NOTE: After installation of the hydrostatic pump, the hydrostatic travel control must be adjusted. See "Hydrostatic / Treadle Pedal Adjustments" later in this chapter.
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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HYDROSTATIC DRIVE
Coupler Removal And Installation
Removal 1. Remove the bolt (Item 1) from the coupler
1
2. Slide the coupler of the pump shaft. Installation 1. Install the coupler on the pump shaft. 2. When installing the coupler, maintain 2.24 - 2.26 in. (56.9 - 57.3 mm) over all length from the pump housing to the coupler edge. Tighten the coupler bolt to specification.
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Hydrostatic Pump Coupler Bolt: 40 ft-lbs (54 Nm)
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2.24 - 2.26 in. (56.9 - 57.3 mm)
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Hydrostatic Pump Exploded View
1. Snap Ring 2. Seal 3. Bearing 4. Shaft 5. O-ring 6. Cap 7. Race 8. Bearing 9. Plug
5 6 7 9 5
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4 5 9 8 87 7 6 6 5 5 1 10 10 18 15 16 18 19 20 17 1 1 3
1
11
11
13
14 10. Housing 11. Pin 12. Swash Plate 13. Spacer 14. Gasket 15. Piston 16. Keeper Ring 17. Spherical Washer 18. Pin 19. Spring 20. Rotating Block 21. Valve Plate
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HYDROSTATIC DRIVE
Hydrostatic Pump Disassembly
IMPORTANT: When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system 1. Remove the 0-ring (Item 1) from the bottom of the hydrostatic pump. 3. Remove the O-rings (Item 3) from the plate.
3
1
4. Remove the plugs (Item 4) (Both sides).
2. Remove the four bolts (Item 2) retaining the back plate and remove the back plate from the hydrostatic pump.
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5. Remove the O-ring (Item 5) from the plugs.
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HYDROSTATIC DRIVE
6. Remove the valve body (Item 6) from the hydrostatic pump. 9. Remove the springs (Item 9) and relief valves (Item 10) from the valve block.
7. Remove the gasket from the hydrostatic pump and remove the valve plate (Item 7).
7
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13
10. Remove the plugs (Item 11).
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10
11. Remove the O-rings from all the plugs. 12. Remove the spring (Item 12) and the charge pressure relief valve (Item 13). 12
6
8. Remove the relief valve plugs (Item 8) from the valve block.
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HYDROSTATIC DRIVE
13. Remove the rotating block and piston assembly (Item 14) from the housing. 16. Remove the snap ring (Item 17) and seal (Item 18).
17
14
17. Remove the snap ring (Item 19). 14. Remove the pistons (Item 15) from the rotating block.
15
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15. Remove the spherical washer (Item 16).
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18. Remove the shaft (Item 20) from the pump housing. 16 20
10.24
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HYDROSTATIC DRIVE
19. Remove the spacer (Item 21) from the pump housing. 21. Remove the snap rings (Item 24) and the caps (Item 25) from the pump housing.
21
20. If replacing the shaft or bearing, remove the snap ring (Item 22) from the shaft and press the bearing (Item 23) off the shaft.
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25 22. Remove the O-rings (Item 26) from the caps.
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HYDROSTATIC DRIVE
23. Remove the swash plate (Item 27) from the pump housing. 25. Remove the O-rings (Item 1) from the plugs.
1
27
24. Remove the plugs (Item 28) from the pump housing.
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HYDROSTATIC DRIVE
Inspection
1. Inspect the valve plate (Item 1) for scratches or scoring. Replace a valve plate if the scratches are deep enough to catch with a fingernail. 3. Inspect the mating surface of the spherical washer for scoring or scratches (Item 3).
3
1
2. Inspect the pistons, look for scoring and scratches. Ensure the holes (Item 2) in the slippers are not plugged.
2
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4 5
4. Inspect the pins (Item 4). They should all be the same length. Do not remove.
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5. Inspect the spherical washer (Item 5) for scoring and wear.
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6. Inspect the back surface of the rotating block (Item 6) where the valve plate seals. Check for scratches and scoring. 2. Install the plugs (Item 2) into the pump housing.
7 8 6
7. Inspect the spring (Item 7) and C-clip (Item 8) for excessive wear or damage.
Assembly
1. Install the O-ring (Item 1) onto the plugs.
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3. Install the swash plate (Item 3) into the pump housing.
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4. Install the O-rings (Item 4) on the caps. 6. Install the snap rings (Item 6) over the caps.
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5. Install the caps (Item 5).
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6 7. Install the spacer (Item 7) onto the swash plate.
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8. Press the new bearing (Item 8) onto the drive shaft. 11. Install the snap ring (Item 11).
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9. Install the snap ring (Item 9) on the drive shaft.
12. Install the pump seal (Item 12).
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9 10. Install the drive shaft (Item 10) into the pump housing.
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13. Install the snap ring (Item 13).
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14. Install the spherical washer (Item 14) onto the rotating block (Item 15). 17. Install the charge pressure relief valve (Item 19) and spring (Item 20).
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15. Install the pistons (Item 16) into the rotating block (Item 17). 16
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18. Install the o-ring on the plug. Install the plug (Item 21)
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16. Install the rotating block and piston assembly (Item 18) into the housing.
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19. Install the o-ring (Item 22) onto the relief valve plugs.
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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20. Install the relief valves (Item 23), springs (Item 23) and plugs. Torque plugs to specification. 21. Install the alignment pin (Item 24) and valve plate (Item 25).
23 22 24
22. Install the gasket onto the pump housing.
23 22
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Hydrostatic Pump Relief Valve Plug: 20 ft-lbs (27 Nm)
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23. Position the valve body on the housing.
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24. Install o-rings on the plugs and install the plugs (Item 27) into the end cap. (Both sides). Torque plugs to specification. 26. Position the end cap (Item 29) onto the valve body.
29 27
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Hydrostatic Pump End Cap Plugs: 20 ft-lbs (27 Nm) 25. Install the o-rings (Item 28) into the end cap.
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27. Install the four bolts (Item 30.
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HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS
Hydrostatic Travel Control Adjustments
NOTE: The travel control adjustments are listed in the order in which they MUST be performed. Failure to do so will result in poor vehicle performance. 3. Disconnect the neutral safety switch connector (Item 2) and remove the controls cover (Item 3).
WARNING
Be certain that ALL four wheels are safely elevated off the ground before attempting to perform any adjustment procedures. 2. Remove the bolts (Item 1) retaining the controls cover. 3
4. Verify that the speed control cable (Item 4) is attached to the top hole of the engine speed control lever.
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1. Raise the vehicle so all four wheels are off the ground and place on jack stands.
HYDROSTATIC DRIVE
Neutral Adjustment
1. Install a tie strap (Item 1) on the hydraulic hose shown to serve as a pointer on the pump plate. 4. Slowly rotate the pump plate clockwise until the rear wheel starts to rotate. Mark the location of the tie strap on the pump plate (Item 3), using a fine tipped marker.
2. Start the engine, place the AWD / 2WD / TURF Switch in the TURF mode, the gear selector in HIGH and engine speed at high idle (3000 RPM). 3. Loosen the four pump plate mounting bolts (Item 2).
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5. Slowly rotate the pump plate counterclockwise until the wheel stops rotating and then starts to rotate in the opposite direction. Mark the location of the tie strap on the pump plate (Item 4).
2 2
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6. Rotate the pump plate clockwise until the end of the tie strap rests approximately half way between the two marks. By centering the pump plate between clockwise and counterclockwise wheel rotation start points, the pump is now centered in a neutral position. 7. The wheels should not be turning.
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8. Torque the four bolts (Item 5) to specification. 2. Locate PU-51261 - Drive Control Adjustment Wrench (Item 2) and install it as shown.
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Pump Plate Mounting Bolts: 22 ft-lbs (30 Nm) 9. Return the engine to slow idle and shut the engine off. Place the gear selector lever in Park. Proceed to "Travel Cable Adjustment".
Travel Cable Adjustment
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2 3. The Drive Control Adjustment Wrench is used to rotate the pintle lever while maintaining proper spacing between command and pintle levers. 4. Loosen the jam nuts (Item 3) on the travel control cable. 3
1. Secure the travel pedal in the full forward position by placing wood blocks (Item 1) under the rear of the pedal. The travel pedal should remain in contact with the pedal stop on the frame.
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5. The travel control cable (Item 4) will pull the command lever (Item 5) counterclockwise and the HP control spring (Item 6) will pull the pintle lever along with the command lever. 5 4 8. While holding the outer jam nut, torque the inner jam nut (Item 8) to specification.
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Travel Control Cable Jam Nuts: 12 ft-lbs (16 Nm) NOTE: Over tightening the outer jam nut results in overstroking the command lever causing the HP control spring to function improperly.
6
9. Remove the wood blocks (Item 9) from under the foot pedal. Proceed to "Forward Speed Control Cable Adjustment".
6. Apply pressure on the tool in a counterclockwise direction until the pintle lever is held against the internal stop.
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Forward Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the speed control cable (Item 2).
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7. Tighten the outer jam nut (Item 7) until it is tight against the bracket.
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2. After adjustments are made, the protective boot (Item 3) must be in place to prevent cable damage. Proceed to "Reverse Speed Control Cable Adjustment".
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HYDROSTATIC DRIVE
Reverse Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the travel control cable.
Engine Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the speed control cable (Item 2).
1
2
1
2
2. After adjustments have been made, the protective boot (Item 2) must be in place to prevent damage to the cable. Proceed to "Engine Speed Control Cable Adjustment".
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TRAVEL CONTROL (TREADLE) PEDAL
Description
The travel control (treadle) pedal is used to control the forward and backward movement of the vehicle. The farther the pedal is pressed, the faster the travel speed. The travel direction control system requires regular inspection. Inspect the travel direction control system to ensure proper operation. Incorrect adjustment may cause erratic travel speed conditions. 2 3. Check the travel control pedal (Item 2) for excessive freeplay.
WARNING
Failure to check or maintain proper operation of the travel control system can result in an accident and lead to serious injury or death if the travel control pedal or the engine speed control lever sticks during operation. Always inspect the travel control pedal for free movement and return to neutral before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating travel control pedal.
Inspection
1. Position the vehicle on a flat level surface. Position the gear selector lever in Park and stop the engine.
IN
2. Inspect the travel control pedal (Item 1) for free movement. Be sure the pedal returns to the neutral position normally when released.
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Pedal Removal
1
4. The correct amount of total free travel on the travel control pedal is 0.30 in. (7.6mm). 5. While on flat level ground, with the gear selector lever in Park, press the travel control pedal to full forward, the engine speed should be 3650 - 3750 RPM. Repeat with travel control pedal fully in reverse, the engine speed should be 3650 - 3750 RPM. If the specified RPM is not observed or if the travel control pedal does not return to neutral unassisted, reference the "Hydrostatic / Treadle Pedal Adjustments".
1. Remove the bolts (Item 1) and skid plate.
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2. Remove the nut (Item 2) and slide the pedal off the shaft. 2. Disconnect the neutral safety switch connector (Item 2) and remove the pump cover (Item 3).
2
2
Cable Removal And Installation
1. Loosen the cable cover bolts (Item 1).
3. Remove the clip (Item 4), washer and cable end (Item 5) from the command lever.
1
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4. Loosen the jam nuts (Item 6) and remove the cable from the bracket. 7. Loosen the jam nuts (Item 2) and remove the cable (Item 3) from the travel control pedal. 8. For installation, reverse the procedure. Torque fasteners to specification
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6 9.
Perform Hydrostatic Travel Control Adjustments.
5. Remove the ten skid plate screws (Item 7) and skid plate.
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6. Remove the nut (Item 1).
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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Travel Cable Cover Bolts: 7 ft-lbs (10 Nm)
HYDROSTATIC DRIVE
TROUBLESHOOTING
Hydrostatic Drive Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the recommended procedures must be done by authorized Polaris Service Personnel only. PROBLEM No drive on both axles No drive on one axle The hydraulic system is overheating. Drive axles turning at different speeds CAUSE 1, 2, 3, 4, 5, 6, 7, 13, 15 1, 3, 4, 5, 8, 1, 3, 4, 9, 10, 11, 12, 1, 3, 4, 5, 8, 14
KEY TO CORRECT THE CAUSE
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1. Check for drive codes. 2. The directional control is not working correctly. 3. A hydrostatic drive motor has damage. 4. The brake is not releasing. 5. A hydrostatic pump has damage. 6. The accelerator is not working correctly. 7. The charge pressure is low. 8. A replenishing valve not seating. 9.The hydraulic fluid is not at correct level. 10.The hydraulic cooler has a restriction. 11.The hydraulic temperature sender is not working correctly. 12.The cooling fan is not turning 13.Servo enable not working correctly. 14.Two-speed not working correctly. 15.The drive controller is not working correctly.
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