SECTION 2

HYDROSTATIC DRIVE SYSTEM

Specifications 2.1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-3

General Information 2.2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-4

Trouble Shooting 2.3

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-5 ~ 7
2
Diagnose Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-8

Pressure Tests 2.4

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-9

Towing Procedure 2.5

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-10

Flushing The Hydraulic System 2.6

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-12 ~ 13

Start-up Procedure 2.7

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-14

Gear Pump Replacement 2.8

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-15

Tandem Pump Replacement 2.9

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-16 ~19

Tandem Pump Parts Diagram 2.10

Parts Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-20 ~ 23

Drive Motor 2.11

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pg. 2-24 ~ 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-28 ~ 29
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-30 ~ 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-32 ~ 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-40 ~ 44

Torque Specifications 2.12

Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-45

Conversion Chart 2.13

Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 2-46 ~ 47

2-1
 HYDROSTATIC CIRCUIT 2.1
Hydrostatic Circuit and System Pressure Schematic
A High Pressure Relieved at 345 Bar (5000PSI)
B Aux. Press. Relief Set at 2400 PSI (207 Bar)
C System Charge Pressure 200 PSI Minimum (13.8 Bar)

2 D Return Pressure
E Suction Line (Vacuum) 4 - 6 Hg @ 160ºF (71ºC)

D
D

D
A
C E

D
C A
C B

C C4165
C
2-2
 SPECIFICATIONS 2.1
Hydrostatic Tandem Pump
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Displacement, Reversible Piston
Brand Name of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauer-Danfoss
Series Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 / M44
No. Of Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (TWO)
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem
Rotation (viewed from shaft end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 RPM (+ / - 50 RPM)
2
Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.65 cu. in. (44cc)
Minimum Pump Output (flow) . . . . . . . . . . . . . . . . . 17.1 gal. (64.7L) / Minute @ 1800RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . @ 2000 PSI (136.1 Bar) Over Measured Charge Pressure
No. Of Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (TWO)
Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Bar (5000 PSI)
Max. Allowable Case Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PSI (1.7 Bar)
Charge Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6cc/rev. Geroter Style
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 PSI Min. (13.8 Bar)
Hydrostatic Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thomas P / N 44232
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauer Sundstrand P / N BLN-9992

Hydraulic Drive Motor

Drive Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Geroter Torque Motor With Brake
Brand Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauer-Danfoss
Series Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TMT 500 FLV
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual
No. Of Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (TWO)
Drive Motor Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.9 cu. in. (523cc)
Max. Case Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 PSI (17.3 Bar)

Reservoir
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10w30 API Class SJ Oil
Reservoir Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One 100 Micron Screen Element
Hydraulic Oil Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One 5 Micron Element
Hydraulic Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P / N 35243

2-3
 GENERAL INFORMATION 2.2
Introduction:
Counterclockwise Variable displacement Fixed displacement
swash plate rotation piston pump drive motor
Case drain

2 Clockwise input
shaft rotation
High pressure

Charge pressure inlet

High pressure
High pressure
C3760

The driveshaft of the piston pump is rotated by the engine. The When the swashplate begins to move the check valve on the dis-
piston block which is splined to the driveshaft also turns. The charge, or pressure, side seats because of the higher pressure
piston block, rotating group, consists of 9 piston assemblies differential. The other check valve remains open on the intake
which have free swiveling shoes swagged on the ball end of or low pressure side to continue supplying the closed loop sys-
each piston assembly. The shoe end of the piston rides against tem with charge oil.
the smooth machined surface of the swashplate. With the swash- The drive motor, which is a fixed displacement type, delivers a
plate in the neutral position, the piston assemblies do not recip- constant output torque for a given pressure throughout the speed
rocate in the piston block, but are rotating. No oil is drawn into range of the motor.
or discharged from the pump. The pump is in a zero displace- The movement of the pump swashplate, forward or reverse,
ment position and the loader remains stationary. controls the direction of the drive motor rotation.
With the swashplate in the neutral position, the pressure of the The function of the pressure relief valve is to relieve the pres-
charge oil, which ranges from 200 psi (13.8 Bar), is able to sure side of the system of excessive high pressure when the
unseat both check valves and supply oil to both sides of the loader encounters a heavy load or stalls out.
pump because of the balance in pressure. Very little charge oil When the relief valve senses an over load it unseats, allowing
volume is required in the neutral position so the excess oil is excess pressure and volume to flow into the low pressure side of
bypassed over the charge pressure relief valve and recirculated the pump. A small volume of oil starts to flow across to the
back to the reservoir. The oil that leaks internally in the pump other relief valve. This relief valve is exposed to the low pres-
and motor collects in their body housings and is returned to the sure on the intake side of the pump and is seated by the spring
reservoir by external case drain in the pump and motors. This tension within the relief valve body.
leakage oil is the only oil the charge check replenishes. This
makes the design a closed loop system. The small volume of oil being bypassed is enough to unseat the
relief valve and let it recirculate back into the inlet side of the
As the steering lever is moved forward, or reverse, the loader pump. As the pressure continues to build on the pressure side, a
starts a directional movement. As the swashplate begins to larger volume of oil flows and at a greater speed through the
move, the piston assemblies start to reciprocate in the piston drilled orifice in the relief valve cartridge, causing a pressure
block. As the steering lever continues further movement the cam drop inside the relief valve. The surrounding pressure is now
angle increases, the pistons reciprocate further, more oil is able to unseat the relief valve and bypass maximum volume of
pumped and the speed of the loader is increased. oil. The system reliefs function the same for both sides of the
system.

2-4
 TROUBLE SHOOTING 2.3
Symptom: Neutral Difficult Or Impossible To Find

Inspect external
control linkage

Defective
OK
2
Repair or
replace

Symptom: System Operating Hot

Check oil level Inspect heat Check charge

OK exchanger OK pressure
in reservoir

Below level Defective

Low
Fill to proper Repair or
level replace

Inspect charge Inspect inlet Inspect charge

pump OK OK relief valve
screen or filter

Defective Clogged Defective

OK
Repair or Replace Repair or
replace replace

Replace pump Check system

and motor OK Inspect motor OK pressure

Defective High

Repair or Reduce system

replace load

2-5
 TROUBLE SHOOTING 2.3

Symptom: Operates In One Direction Only

2 Inspect external
control linkage

Defective
OK
Inspect system
relief valves

Defective

Repair or Repair or
replace replace

Symptom: System Response Sluggish

Check charge Inspect

OK
pressure motor

Defective

Low OK
Repair or
replace

Inspect charge Inspect inlet Inspect charge Replace pump

OK OK OK and motor
relief valve screen or filter pump

Defective Clogged Defective

Repair or Replace Repair or

replace replace

2-6
 TROUBLE SHOOTING 2.3

Symptom: System Will Not Operate In Either Direction

Check oil level

in reservoir

Below level
OK
Check external
control linkage

Defective
OK
Check charge
pressure
2
Low
Fill to proper Repair or OK
level replace

Inspect charge Inspect inlet Inspect charge

pump OK OK relief valve
screen or filter

Defective Clogged Defective

OK

Repair or Replace Repair or

replace replace

Replace pump Check sys-

and motor OK Inspect motor OK
tem pressure

Defective High

Repair or Reduce sys-

replace tem load

2-7
 TROUBLE SHOOTING 2.3
System Diagnosing Steps And Special Tools
1 Check oil level in reservoir: 0 - 500PSI (34.5Bar) 0 - 5000PSI (345Bar)
a .fill to proper level as marked on site tube.

2
2 Inspect external control linkage for:
a. misadjustment or disconnection
b. binding, bending or breakage
c. misadjusted, damaged or broken hydroback
3 Inspect servo control valve for: ( if used )
a. proper inlet pressure
b. misadjusted or damaged neutral return spring
c. galled or stuck control spool
d. galled or stuck servo piston Pressure gauges
4 Inspect heat exchanger for: C1699
a. obstructed air flow
b. improper plumbing ( inlet to outlet )
c. obstructed fluid flow
5 Inspect inlet filter or screen for:
a. plugged or clogged screen or filter
b. obstructed inlet or outlet
c. open inlet to charge pump ( open line )
6 Check charge pressure: Vacuum gauge
a. follow test procedures section 2.5 30in. Hg
7 Inspect charge relief valve for:
a. poppet held of seat
b. damaged or broken spring C1704
c. damaged valve seat
d. improper charge relief setting
8 Inspect charge pump for:
a. broken or missing drive coupling
b. damaged or missing o-rings
c. galled or broken geroter set
9 Inspect system relief valves for:
a. damaged or broken springs
b. valve held of seat
c. damaged valve seat
d. improper pressure relief settings
10 Check system pressure: C1698
Adapter fittings
a. follow test procedures section 2.5
11 Inspect hydraulic motor for:
a. disconnected coupling Caps and plugs

Photographs in the right hand column show some of the

special tools that may be required to diagnose and repair
the hydrostatic system.

C1697

2-8
 PRESSURE TESTS 2.4
The following photos show the various port locations
available on the hydrostatic tandem pump for checking
system pressure.
Completing these pressure test will diagnose any mechan-
ical problem in the hydrostatic system. LH side and top view

WARNING
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.
High pressure relief valves D and B Guage port B

2
Gauge port A E
Installing a gauge into the high pressure gauge ports ‘A’,
‘B’ , ‘C’, or ‘D’ will verify the status of the high pres-
sure relief valves. F
Checking the pressure at port ‘E’ will give accurate
charge pressure reading. Gauge portD
Checking the pressure at port ‘F’ will verify case drain C4197 Charge pressure relief valve
pressure.
Measuring the vacuum at the charge pump inlet can help
locate the inlet lines and filters. It would be necessary to
tee into the charge pump line fitting. NOTE: Internal charge pump model shown
Snubbers are recommended to protect the gauges from
pressure spikes. Frequent gauge calibration is necessary
to insure accuracy. RH side and bottom view
Gauge Information Port B Port C
A System 10,000 PSI Gauge (690 Bar) Port D
Port A
Pressure 9/16 - 18 O-Ring Fitting
B Gauge
C System G
10,000 PSI Gauge (690 Bar) Gauge port C
Pressure
D 9/16 - O-Ring Fitting
Gauge
Charge
500 PSI Gauge (34.5 Bar)
E Pressure
7/8 - 14 O- Ring Fitting
Gauge Port
Case
500 PSI Gauge (34.5 Bar)
F Drain High pressure relief valves A and C
1 - 1/16 - 12 O-Ring Fitting C4198
Port
Charge
Vacuum Gauge (30 in. Hg)
G Pump Inlet WARNING
Tee Into Charge Pump Inlet
Vacuum
Raise the machine securely from the ground before
Tandem pump flow can also measure pump performance. performing system checks to prevent sudden move-
1 Connect a flow meter between the high pressure ment.
ports, one section at a time.
2 Start the engine and increase operating speed
between 1775 ~ 1800 RPM.
3 Restrict the flow to show 2000 PSI (137.8 Bar) over
charge inlet pressure.
Example: Charge pressure = 220 PSI (15.2 Bar) Gauge
pressure reading would need to be 2220 PSI (153 Bar).
4 Minimum flow reading should be 17.1 gal / min.
(64.7 L / min).
2-9
 TOWING 2.5
Towing Procedure Relief valve location
In the event the loader has malfunctioned or failed, the
loader may be moved a short distance by following the
procedure below.

2 WARNING
Failure to follow the proper towing procedure may
cause damage to the hydrostatic drive system.

1 Remove the seat and hydrostatic shield.

2 Loosen the high pressure relief valve caps 4 complete C3665
turns. There are 4 high pressure relief valves, 2 on the top Brake release plunger
side, and 2 on the bottom side of the tandem pump. Be
sure to loosen all 4. ( fig. C3665 ) Torque caps 30 to 50 ft
/ lbs (41 to 68 N.m.) upon reassembly.
3 The loader parking brake system is released by
hydrostatic pressure. To release the parking brake when
the unit has failed you must pressurize the brake system
manually. A service override for the brake valve has been
incorporated for use by Thomas Dealers. The normal
position of the plunger is down and turned into the locked
position. To release the brake, turn the release plunger
counter clockwise. (fig. C3666) Access of the small quick Brake valve
connector for the 175 in the engine compartment. C3666
(fiq.C3870) Access the small quick connector for the
1700 in the tandem compartment (fiq. C3871) Use a port Brake release coupler Brake release coupler
-a - power to pressurize this line to 200 psi (13.8 bar).
The brakes are now released.

WARNING
Be sure to return the brake valve plunger to the
normal position after servicing the loader.

CAUTION C3870 C3871

To prevent damage to the drive motors, do not
exceed speed of 1 MPH.

4 Use the front frame mounted tie downs to attach

pulling devise. ( fig. C3447 ) Use the rear tie downs to Rear tie
pull the loader backwards. ( fig. C3446 ) down

WARNING
Use chains or cables rated a minimum of 1 and 1/2
Front tie down
times the gross vehicle weight.
C3447 C3446

2-10
FLUSHING THE HYDRAULIC SYSTEM 2.6

General Information
Contamination in the hydraulic system is a major cause of The best way to remove contaminates from the hydrostat-
component failure. Contamination can enter the hydraulic
system in any of the following ways:
1 When draining the hydraulic system.
2 When disassembling components.
3 Making auxiliary connections with dirty couplers.
ic drive system is to disassemble each component and
flush and clean thoroughly.
The hydraulic control circuits may be cleaned by attach-
ing a suitable hydraulic filter to the auxiliary couplings
and circulating the fluid through it.
2
4 Normal component wear.
5 Component failure

Contamination Types
There are 2 types of contamination, microscopic, or non Visible contamination is foreign material that can be
visible, and visible. Microscopic contamination is sus- found by sight, touch or odor. Some examples of visible
pended in the fluid and moves freely through the contamination include the following:
hydraulic circuits. Examples of problems caused by 1 Particles of metal or dirt in the oil.
microscopic contaminates include the following: 2 Air in the oil.
1 Cylinder rod seal leaks. 3 Odor of burned oil.
2 Control valve spools do not return to neutral. 4 Water in the oil.
3 Hydraulic system has a high operating temperature.
4 Components wear rapidly.

2-11
 FLUSHING THE HYDRAULIC SYSTEM 2.6
Cleaning The System Hydraulic reservoir

The first step in cleaning the hydraulic system is to deter-

mine if you have visible or microscopic contamination.
If the contamination is visible, do the following steps:

2 1 Change the hydraulic oil by removing the drain plug

in the bottom of the hydraulic oil reservoir. (fig. C3661)
Be prepared to contain approximately 56 litres(14.8 gal)
of fluid.
2 Check the extent of the contamination by disassem-
Oil drain plug

bling 1 each of the hydraulic cylinders. Check the cylin-

ders for damage. Repair or replace the cylinders as
C3661
required. If you determine the damage was caused by
severe contamination and is not the result of normal wear, Flush the fluid to an external trap filter
it will be necessary to remove, clean and repair all valves,
pumps, lines, cylinders, etc.
3 Replace all hydraulic filters.

If the contamination is determined to be microscopic, per-

form the following steps:
1 Change the hydraulic oil by removing the plug in the
bottom of the oil reservoir. (fig. C3661) Be prepared to
contain approximately 56 litres (14.8 gal) of fluid.
2 Connect an external 5 micron filtering system, capa-
ble of sustaining minimum of 2000 PSI (138 Bar) and has C3646
a back pressure gauge, to the auxiliary couplings. (fig.
C3646) Replace the hydraulic filter
3 Start the engine and let it idle at approximately half
throttle.

WARNING
Be sure to use a filtering system capable of handling
the pressure of the hydraulic system.

4 Engage the auxiliary circuit. Check to make sure the

filtering system is not over taxed by the loaders hydraulic
system pressure. Adjust engine idle accordingly to match C3650
the filtering systems capacity. This may vary as the filter
becomes dirty, you may need to decrease engine RPM. Hydraulic reservoir sight gauge
Circulate the oil through filter for 30 minutes.
5 As the oil is being circulated through the auxiliary
circuit, raise the liftarms up and down in full stroke
cycles. Repeat this exercise for 15 minutes.
6 Cycle the bucket tilt cylinders in the same manner as
above. Repeat the exercise, in full extension and retrac- Oil level
tion, for 15 minutes.
7 Install new hydraulic oil filters. (fig. C3650)
8 Start the engine and check for leaks. Replenish the
hydraulic oil reservoir as required. (fig. C3431)
C3431

2-12
FLUSHING THE HYDRAULIC SYSTEM 2.6
For flushing water from the hydraulic system, perform
the following procedures:
1 Remove any attachment.
2 Make sure all cylinders are fully retracted.
Reservoir drain plug
IMPORTANT
Be sure attachments are removed and liftarm are in
the lowered position.

3 Change the hydraulic fluid. (fig. C3661)

4 Change the hydraulic filter. (fig. C3650)
2
5 Disconnect the hydraulic lines from one set of cylin-
ders. (fig. C3601, C3441) C3661
6 Start the engine and set to the lowest idle.
7 Have someone hold the open hydraulic lines into a Replace hydraulic filter
container. Stroke the foot pedals, or hand operated, con-
trols slowly. Continue to repeat this cycle until the oil
comes out clear. Repeat for opposite set of cylinders.

WARNING
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.

8 Attach a hose and couplings to the auxiliary circuit. C3650

Engage the auxiliary hydraulics, forward and reverse,
until the oil flows clear.
Disconnect hydraulic lines
9 Connect 1 hose each, on each cylinder, to the fixed
end of the cylinder barrel.

IMPORTANT
Check the hydraulic oil frequently during this pro-
cedure. Replenish as required.
10 Move the foot pedal or control lever to extend the
cylinder rods. This will flush the oil from inside the cylin-
der barrels. Be prepared to contain the waste oil.
11 Stop the engine.
12 Connect the hydraulic hoses to the rod end of the C3601
cylinder barrel.
13 Replenish the hydraulic oil as required. Disconnect hydraulic lines

IMPORTANT
Please contain and dispose of waste oil in an envi-
ronmentally friendly manner.

C3441

2-13
 START-UP PROCEDURE 2.7
The following start-up procedure should always be
adhered to when starting up a new installation or when
restarting after pump repairs have been made.
1 Fill the hydraulic oil reservoir to the proper level.
( fig. C3431)

2 2 The inlet hose from the oil reservoir to the charge

should be filled with oil prior to starting.
3 Check inlet and pressure hose fittings for proper
tightness prior to starting.
4 The pump must be filled prior to start-up with fil-
tered oil. Fill the pump by pouring oil into the side case
drain port. (fig. C4197 location “D” ) D
C4197
WARNING Solenoid wire connector
This start-up procedure must be made with the
loader securely raised off the ground.

5 Disconnect the engine stop solenoid wiring, or

remove the fuse connected to the red wire. (fig. C3872)
6 Turn the engine over by engaging the starter. Repeat
this step, turning the engine over in 15 second interval, 5
or 6 times. This will fill the rest of the hydraulic hoses.
7 Reconnect the engine stop solenoid or replace the
fuse.
8 Start the engine and let idle at lowest possible set-
ting. C3872
9 Check for leaks and make adjustments as required.
Do not use your hands to check for leaks while the engine
is operating.
10 Replenish the hydraulic oil reservoir as required.
11 Start the engine and increase the RPM’s to half throt-
tle. Bring the hydraulic fluid up to operating temperature
and make control adjustments as outline in Section 4.

WARNING
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene- C1108
trate the skin and cause serious injury.

Reservoir sight gauge

C3431

2-14
 GEAR PUMP REPLACEMENT 2.8
Start the gear pump removal procedure by removing any
Reservoir filler spout
attachment, raising the boom arms and engaging the
boom support pins. Shut off the engine. Vacuum
1 Remove the seat and hydrostatic shield.

WARNING
To prevent personal injury do not work under the
boom arms without the boom supports engaged.

2 Attach a vacuum system to the hydraulic oil reservoir

filler location. ( fig. C3428 ) Or drain the oil reservoir.
2
Seal the threads on the drain plug, if removed, with teflon
C3428
tape or a liquid form of pipe sealant before reinstalling.
3 Disconnect the hydraulic hoses from the gear pump.
( fig. C3448 ) Remove the pump fittings. Cap all open
hoses to prevent contamination. After capping ends you Hoses
may unhook vacuum system from oil reservoir.
4 Remove the 2 bolts holding the gear pump to the
hydrostatic tandem section. ( fig. C3449) Remove the
gear pump.
5 Replace gear pump in reverse order.

IMPORTANT
If gear pump replacement is being done because of
failure, the hydraulic system and oil should be C3448
checked for contamination.

6 If the hydraulic system has been contaminated by

Bolts
pump or other failure you must follow the cleaning proce-
dure outlined in section 2.7.
7 Start the engine and check for leaks. Do not use your
hands to find leaks.

WARNING
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.

8 Check the fluid level in the hydraulic oil reservoir C3449

and replenish as required. (fig. C3431)

IMPORTANT Oil level

When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open lines and ports.

C3431

2-15
 TANDEM PUMP REPLACEMENT 2.9
Begin the pump removal by removing any attachment,
raise the boom arms and engage the boom support pins. Tandem case drain hose

WARNING
To prevent personal injury do not work under the

2 boom arms without the boom supports engaged.

Shut off the engine.

1 Remove the seat and hydrostatic shield.
2 Remove the steering lever linkage. Refer to section 4
High pressure hoses

for removal and replacement information.

3 Remove the gear pump as out lined in section 2.9. C3450
4 Disconnect all the hydraulic hoses. (fig. C3450)
Mark hose and fitting location if necessary to ease re- Front mounting bolt
assembly. Upon re-assembly, torque the hydraulic fittings
and hoses as outlined in the Torque Chart in Section 2.13
Cap all open lines and ports.
5 Remove fittings from the tandem pump to prevent
Lower mounting bolt
damage while removing pump. Plug all open ports and
keep the fittings in a clean area. Inspect fittings and o-
rings for damage, replace as required.
6 Loosen the forward lower mounting bolt on the tan-
dem pump mounting bracket. (fig. C3451)
7 Remove the 2 bolts on the u-joint access panel (fig.
C3453) to gain access to the rear mounting bolts for the C3451
tandem pump. Tip the top of the panel rearward and pull
the panel forward to remove.
Access panel bolts
IMPORTANT
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open lines and ports.
8 Attach a lifting device to the tandem pump. The
pump is fairly heavy, approximately 80 lbs. (36 Kg) It is
highly recommended to use a mechanical lifting device to
assist removal of the tandem pump.
9 Remove the 2 rear mounting bolts by access through C3453
the u-joint access panel and remove the front mounting
Access panel open
bracket. Remove tandem pump from the loader.
(fig. C3452)
Pump Mounting Bolts
CAUTION
To prevent possible personal injury, do not attempt
to lift heavy objects without assistance.

C3452

2-16
 TANDEM PUMP REPLACEMENT 2.9
Upon reassembly, inspect the outside area of the tandem
pump housing for damage that may have occurred in tran-
sit or handling.
1 Attach a lifting device to the tandem pump.
2 Install the lower charge pressure inlet fitting to the
tandem pump and attach the brake valve hose. (fig.
C3478) Follow the torque chart on page 2 - 43.
3 Install the tandem pump to the loader.

WARNING
2
Charge pressure inlet fitting
To prevent personal injury, do not attempt to lift
heavy objects without assistance. C3478

Line up pump spline to u-joint yoke

4 Line up the u-joint to the tandem pump input splined
shaft as you guide the pump into it’s mounting location.
( fig. C3479)
5 Install the 2 rear mounting bolts.
6 Line up the front mounting brace holes and install the
bolt. (fig. C3451)
7 Torque the 2 rear mounting bolts to 60 ft/lbs. (82
N.m.) Torque the front pump bracket mounting bolt to 50.
(68 N.m.) Torque the front lower mounting bracket bolt at
20 to 25 ft/lbs. (32 N.m.) Remove the lifting device.
C3479

8 Connecting the 4 high pressure drive hoses and fit-

tings to the tandem pump can only be accomplished in a
certain sequence. (fig. C3480) Follow the Torque Chart in
Section 2.13, page 2 - 43 when tightening fittings and
hoses. If you have removed the hoses completely use the
following pattern to reconnect:
A Hose no. 4 connects to the bottom port of the right
hand drive motor.
B Hose no. 1 connects to the bottom port of the left Front mounting brace Bolt
hand drive motor.
C Hose no. 2 connects to the top port of the left hand
drive motor. Lower mounting bolt
D. Hose no. 3 connects to the top port of the right hand C3451
drive motor.
High pressure hose layout

9 Connect the charge inlet hose from the oil filter to

the tandem pump. Torque the fittings and hoses according
to the Torque Chart in Section 2.13 page 2 - 43.

IMPORTANT 2
3
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs 1
on all open line and ports C3480 4

2-17
 TANDEM PUMP REPLACEMENT 2.9
10 Connect the tandem pump case drain fitting and
Case drain connection
hose. Torque the fittings and hoses to the specifications
listed in the Torque Chart in Section 2.13 page 2 - 43.

2 IMPORTANT
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open line and ports.

C3481 (1700 shown)

11 Connect the auxiliary gear pump outlet fittings and
hoses to the gear pump. (fig. C3482) Follow the Torque
Chart in Section 2.13 page 2 - 43 when tightening fit- Gear pump
tings and hoses.

IMPORTANT
Inspect fitting o-rings and flares for marks or dam- To control valve
age. Replace if necessary.

C3482
12 Connect the inlet fitting and hose to the auxiliary
gear pump. (fig. C3482) Torque the fittings and hoses to
the specifications listed in the Torque Chart Section 2.13. Gear pump

IMPORTANT
Follow the Torque Chart In Section 2.13 when tight-
ening fittings and hoses. From the reservoir

C3482

13 Connect the charge pressure outlet line from the tan- Brake valve
dem pump to the hydraulic brake valve. (fig. C3483)

Charge line

C3483

2-18
 TANDEM PUMP REPLACEMENT 2.9
14 Reinstall the steering control linkages and locks as
outlined in Section 4. and install access cover with 2
bolts. ( fig. C3485 )
Replace control linkage
IMPORTANT
Follow the start up procedure outlined in section 2.8
upon restarting after pump repairs or replacement.

15 Fill the hydraulic oil reservoir to the proper level.

16 Follow the start up procedure outlined in section 2.8
2
before attempting to start the loader.
17 The start up must be made with the loader raised
C3485
securely from the ground. Changing the pumps and the
steering control linkages has affected the neutral adjust-
ment. Failure to raise the loader clear of the ground may Hydraulic reservoir filler cap
result in the loader engaging in motion and possibly caus-
ing serious injury.

WARNING
This start-up procedure must be made with the
loader securely raised off the ground.

18 Start the loader and check for leaks. Make repairs as

necessary and replenish the hydraulic oil reservoir (fig.
C1108, C3431). Never use your hands to check for
hydraulic leaks. C1108

WARNING Reservoir sight gauge

To prevent personal injury never make repairs to the

hydraulic system while the engine is operating.

19 Make adjustments to the steering controls, steering

locks, and restraint bar cables as required. Follow the pro-
cedures for control adjustments in Section 4

WARNING C3431
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.

2-19
 TANDEM PUMP PARTS DIAGRAM 2.10
Danfoss Series 40 Rear Pump 35
36
1

2
2

3 37

1 38 50
4 39
5 40

4 41
42
6
43
44
7
45
8 46
47
9

27 10

11 48

11
10
12
9
19
18 49
13 15
20
16 21 51
17 28
14

34
15

22 23 24 25 26 33
21
51
32
20 15
29
30
19
31
C1881

2-20 2-20
 TANDEM PUMP PARTS DIAGRAM 2.11
Rear Pump Diagram C1881 Index
1. Retaining ring
2. Seal support washer
3. Input seal
4. Retaining ring

2
For further service instructions refer to a Sauer
5. Bearing Danfoss Dealer and request a Service / Repair Manual
6. Drive shaft #BLN 9992
7. Bolt
8. Cover
9. O-ring seal
10. Bearing
11. Plug
12. Swashplate seal
13. Swashplate cover
14. Bolt
15. Dowel pin
16. Gasket
17. Plug
18. Bearing
19. Relief valve
20. O-ring seal
21. O-ring seal
22. Charge relief plug
23. O-ring seal
24. Charge relief shims
25. Charge relief spring
26. Charge relief poppet
27. Pump housing
28. End cap
29. Plug
30. O-ring seal
31. O-ring seal
32. Coupler
33. O-ring seal
34. Screw
35. Swashplate
36. Thrust plate
37. Piston assembly
38. Slipper retainer
39. Slipper retainer guide
40. Special washer
41. Slipper hold down pins
42. Hold down pin retainer
43. Cylinder block
44. Washer
45. Spring
46. Washer
47. Retaining ring
48. Valve plate
49. Spring pin
50 Cylinder block kit
51. Relief valve kit
2-21
 TANDEM PUMP PARTS DIAGRAM 2.10
Danfoss Series 40/ M44 Front Pump 43
42

2 25 19
41
40
39

38 26
20
37
21 36
44
22
35

17 17 34
33
16 32
31
28 18
7

8
15 30
24
21 9
20 23 29
10
19
25 11
15

11
15 27

10
12 5

9
13 2
3

2
14 1

C2007

2-22
 TANDEM PUMP PARTS DIAGRAM 2.10
Front Pump Diagram C2007 Index
1. Retaining ring
2. Seal support washer

2
3. Input seal For further service instructions refer to a Sauer
4. Retaining ring Danfoss Dealer and request a Service / Repair Manual
5. Bearing #9992
6. Drive shaft
7. Bolt
8. Cover
9. O-ring seal
10. Bearing
11. Plug
12. Swashplate seal
13. Swashplate cover
14. Bolt
15. Dowel pin
16. Gasket
17. Plug
18. Bearing
19. Relief valve
20. O-ring seal
21. O-ring seal
22. Plug
23. Screw
24. Bracket
25. Relief valve kit
26. Cylinder block kit
27. Pump housing
28. End cap
29. Swashplate
30. Thrust plate
31. Piston assembly
32. Slipper retainer
33. Slipper retainer guide
34. Special washer
35. Slipper hold down pins
36. Hold down pin retainer
37. Cylinder block
38. Washer
39. Spring
40. Washer
41. Retaining ring
42. Valve plate
43. Spring pin

2-23
 DRIVE MOTOR 2.11
General Information

C3873

GEROTER ASSEMBLY

The basic geroter design uses a combination of mechani-

cal and hydraulic principles that are utilized in the high
torque, low speed motors.
The outer ring ( fig. C153 ) of the geroler assembly is
similar to an internal gear that is held in a fixed position
by securing it to the motor housing. The rotating inner
gear, called a star, orbits inside the secured outer ring.

C153

Because of the different number of teeth on the star and

outer ring, the star rotates in an eccentric circular orbiting
motion from the housing center line. ( fig. C154 )

C154

2-24
 DRIVE MOTOR 2.11
A drive shaft is used to transmit the rotation of the star to
the output shaft. The drive shaft has crowned external
splines to match the internal splines in the star and output
shaft. This type of drive is used because the star center

2
line continuously changes during rotation.
As the star orbits, it causes a continuous opening and
closing of the outer ring fluid pockets. Half of these fluid
pockets are subject to fluid pressure, causing star rotation,
and the opposing half are connected to the return line.
When pressure is introduced into the fluid pockets on the
right side of the star ( fig. C156 ) the output rotation will
be counterclockwise. When the fluid pockets on the left
side of the star are pressurized the output shaft rotation
will be clockwise.

C156

To seal the fluid pockets the torque motor incorporates a

rotating roller type seal. ( fig. C157 ) This type of a
rolling seal reduces friction at the star points providing
increased efficiency and reduced component wear.

C157

2-25
 DRIVE MOTOR 2.11
The geroter (fig. C3487), is both a fluid displacement 8 point star Roller (9)
motor and a gear reducer. It provides 8 times (the number
of star points) greater power per revolution than a gear,
vane or piston type motor. This means that 8 times the
greater torque can be developed at one eighth the speed

2 without further gear reduction.

Fluid pockets (9)

C3487

Example shown in fig. C166 is one complete star orbit, or

one sixth of the output shaft rotation.The star must travel
through 6 complete orbits for each single rotation of the
output shaft creating a speed reduction of 6 to 1. The use
of 7 fluid power pockets with the 6 to 1 ratio provides 42
fluid power cycles per each complete shaft revolution.
NOTE: Actual star point count is 8. This is only an
example.

C166

2-26
 DRIVE MOTOR 2.11
For smooth and continuous motor output rotation, the C3488
torque motor utilizes a disc valve which operates in syn-
chronization with the geroler star. The disc valve arrange-
ment consist of a stationary balance plate, rotating disc
valve and a stationary valve plate.

2
The disc valve contains an inlet fluid passage port for
each star valley and a return fluid passage point.
A separate crowned driveshaft is used to synchronize the
disc valve and the geroler star so that they turn as one. To
accept fluid from the disc valve, the valve plate also con-
tains internal porting passages to each outer ring pocket
area.

C3873

Fluid enters the housing through the inlet port and is valve opens to allow the fluid in the pocket area to pass
directed to the balance plate. The balance ring contains an back through the valve plate, disc valve, balance plate
inner and outer seal to separate the high and low pressure and out through the housing return port, as the pocket
fluid passages. Fluid passes through the stationary bal- closes.
ance plate to the rotating disc valve. The rotating disc The disc valve is timed to the gerotor rotor star to govern
valve ports the fluid to the stationary valve plate and the the the inlet fluid flow to the output shaft rotation. If the
proper side of the geroter pockets causing the rotor star to timing of the disc valve to the geroter star is off one
turn. tooth, the relationship of input fluid flow to output motor
As the rotor star rotates, and each fluid pocket reaches its shaft rotation will be reversed.
full open position, the return porting in the rotating disc

2-27
 DRIVE MOTOR 2.11
Removal
1 Remove any attachment, raise the boom arms and
engage the boom support pins. Upper fill check
2 Raise the loader securely off the ground.

2 3 Remove the wheels on the side to be repaired.

4 Drain the oil from the final drive housing. Be pre-
pared to contain approximately 17 litres (4.5 gal) of fluid.
(fig. C1888)
Oil drain plug

WARNING
C3489
To prevent personal injury do not work under the
boom arms without the boom supports engaged.
Inspection cover

5 Remove the seat and hydrostatic shield.

6 Remove the final drive inspection cover located
between the axles of the final drive housing.(fig. C3489)
7 Disconnect the chain as outlined in Section 3.

C3489

8 Remove the 2 high pressure hoses from the drive Hi - pressure hoses
motor. ( fig. C3490 ) Cap the open hose ends and fittings
to prevent contamination.

IMPORTANT
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open line and ports.
C3490

9 Disconnect the 2 brake line hoses and cap the hoses

and adapter fittings in the drive motor. (fig. C3490)
10 Remove the adapter fittings from the drive motor.
Plug the open ports in the drive motor to prevent contam - Brake hoses
ination.

C3490

2-28
 DRIVE MOTOR 2.11
Removal
12 Remove the jam nuts, mounting nuts and lock wash-
ers from the 4 mounting bolts retaining the drive motor to Nuts
the final drive housing. (fig. C3491) Hold the head of the
bolts from inside the final drive housing. (fig. C3492)
13 Remove the drive motor. Seal the drive motor with
silicone upon reassembly.
14 Upon reassembly torque the 4 mounting nuts to 80
lbs / ft.
2
15 If the drive motor replacement is being performed
because of major parts failure, such as geroter damage,
C3491
the hydraulic system must be checked for contamination
and flushed if necessary as outlined in Section 2.7.
Torque motor mounting bolt

C3492

16 If you are installing a new drive motor, remove the Drive sprocket
drive motor sprocket and bolt if you wish to reuse the
sprocket. (fig. C3493)

C3493

17 Install the sprocket, machined washer, lock washer

and bolt. Apply Loctite 242 (blue) to the threads of the
bolt before torquing (fig. C3767) and torque the bolt to 40
Apply loctite
lbs / ft. (54 nm).

C3767

2-29
 DRIVE MOTOR 2.11
Replacement Clean sealing area
1 Clean the mounting areas thoroughly that need to be
sealed with silicone. (fig. C3494, C3495)

2
C3494

Clean sealing area

C3495

2 Apply a bead 1/4 of an inch thick around the drive Apply silicone
motor bearing retainer and around each mounting hole.
(fig. C3667)
3 Install the drive motor and sprocket assembly to the
final drive housing.
4 Install the 4 bolts, lockwashers and mounting nuts
and torque to 80 lbs / ft. (115 nm.)
5 Install the 4 jam nuts. Torque the jam nuts to 40 ~ 60
lbs / ft. (54 ~ 81 nm.)

C3667

6 Replace the master link in the dive chain. Section 3.

shows chain replacement procedure.
Upper check plug
7 Add oil to the final drive housing until it trickles out
the upper check plug hole. This will require approximate-
ly 17 litres (4.5 gal) of 10w30 API SJ (fig. C3496)

C3496

2-30
 DRIVE MOTOR 2.11
IMPORTANT Clean sealing area
Refer to the torque chart in Section 2.13 when tight-
ening hydraulic hoses and fittings

IMPORTANT
Inspect fitting o-rings and flares for marks or dam-
age. Replace if necessary.
2
C3495

8 Install the adapter fittings to the drive motor.

9 Install the brake lines to the drive motor. (fig. C3490)
Brake hoses
WARNING
Use caution when dealing with hydraulic fluid under
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.

10 Install the high pressure drive hoses. (fig. C3490)

11 Clean the final drive housing and inspection cover
thoroughly before applying silicone sealant. (fig. C3495)
12 Install the inspection cover. When installing the nuts, C3490
do not over tighten. The mounting torque should not
exceed 11 lbs / ft. (15 N.m.)
14 Start the engine and check for hydraulic leaks. Do Hi - pressure hoses
not use your hands to trace hydraulic leaks. Shut off the
engine and inspect each fitting for proper torque.

WARNING
To prevent personal injury never make repairs to the
hydraulic system while the engine is operating.

15 Install the wheels and torque the nuts at 100 to 110

lbs / ft. (136 to 149 nm.)(fig. C3497) C3490
16 Install shields and seat, let loader down to ground
and test drive to check performance. Torque the wheel nuts

C3497

2-31
 DRIVE MOTOR 2.12
Parts Illustration
20 C4168
TMT 500 FLV 21

2
19
1. Bolts
2. End Cover
3. Flushing Spool 18
4. Name Plate 17
5. Spacer 16
6. Springs
7. Restrictor 15
14
8. Spring Washer
13
9. O Ring
10. O Ring
11. Ring
12. Balance Plate
13. O Ring 12
14. Disk Valve 10
15. Retaining Ring
16. Valve Drive shaft 8
9
17. Channel Plate 6
18. Guide Pins 3
5 4
19. O Ring
20. Gear Wheel
21. Cardon Shaft

11

2
7

Fig. C4168 shows an exploded view of the hydraulic

torque motor. Before disassembling the torque motor,
clean the outer surface of all loose dirt and grease. Dry 1
with compressed air. Be sure all openings are plugged to
prevent dirt from entering the torque motor.

WARNING IMPORTANT
To avoid eye injury, use safety goggles when When making repairs to the hydraulic system, keep
cleaning with compressed air. the work area and parts clean. Use caps and plugs
on all open line and ports.

2-32
 DRIVE MOTOR 2.12
Parts Illustration
C4169
TMT 500 FLV

1. Screws
2. O Ring
3. Bearing Housing
4. Spring Plate
5. Piston
19

18
2
6. O Ring 17
11 16
7. Spacer Disc 15
8. Shaft Bearing Retainer 10
9. Screws
10. Outer Brake Disc 9
11. Inner Brake Disc
12. Screw 8
13. Bearing
14. Splined shaft 7
6
15. O ring 5
16. Screws
17. Retaining ring 4
18. Shaft Seal
19. Bearing Housing
13

12

14
2

WARNING IMPORTANT
To avoid eye injury, use safety goggles when When making repairs to the hydraulic system, keep
cleaning with compressed air. the work area and parts clean. Use caps and plugs
on all open line and ports.

2-33
 DRIVE MOTOR 2.11
Disassembly
1 Stand unit on end and use a collar or vice to support
shaft. (fig. C3505)

2
C3505
2 Alternate the removal of each bolt (9) as the balance
plate will un-spring when the final bolt is removed. (fig. Bolts (9)
C3506)

C3506

3 Lift off the end cover and note that the spacer may Spacer
still be in the balance plate or on top of the drive shaft.
(fig. C3507)

C3507

4 On a metal surface, hit the valve housing on the side

to release the balance plate and springs. (fig. C3508)

C3508

2-34
 DRIVE MOTOR 2.11
Disassembly (cont’d) Disk Valve Guide Pins(3) Springs(5) Bolts(9)

2
Balance Plate Shuttle Housing
Spacer
C3509

5 Use a 6mm Allen key to remove the flushing valve Shuttle valve plug
plug. (fig. C3510)

C3510

6 Below the plug, the spring guide and the spring are
easily removed. (fig. C3511) Spring Plug

Spring Guide

C3511

7 The flushing spool is deep within the housing and is Flushing Spool
very difficult to remove with a magnet. A pair of long
thin pliers works much better. (fig. C3512)

C3512

2-35
 DRIVE MOTOR 2.11
Disassembly (cont’d)
8 Carefully remove spool from the housing to avoid Spool
scoring. (fig. C3513)

2
C3513
9 Remember that the spool is set at an angel within the
housing. (fig. C3514)

Spool

C3514

10 The second spring is deep within the housing. It is

not necessary to remove this spring unless it is suspected Second Spring
of failure. (fig. C3515)

C3515

11 The complete flushing valve assembly. Carefully Flushing Valve Assembly

examine prior to reinstalling into housing. (fig. C3516)

C3516
2-36
 DRIVE MOTOR 2.11
Disassembly (cont’d) Retaining
Ring Drive Shaft

Channel
Plate

2
C3517

12 Remove the retaining ring, then the channel plate,

RetainingRing
and then lift off the drive shaft which will then expose the
gearwheel and the Cardon shaft. (fig. C3518)

Channel Plate

C3518

13 With the drive section removed, losen the eight (8)

brake cover screws and lift off the housing to expose the
“spring” plate. (fig. C3525, C3526))

C3525

3526
2-37
 DRIVE MOTOR 2.11
Disassembly (cont’d) Brake Disks
14 With the piston removed, the unit can be turned
upside-down to remove the excess oil and the brake disks
(inner and outer). (fig. C3527)

2
C3527

15 With the brake disks removed it exposes the shaft Screws

bearing retainer. Remove the eight (8) screws with a Torx
driver. (fig. C3528)

Shaft Bearing Retainer

C3528

16 Turn the bearing housing and shaft upside-down and

hammer out the output shaft. (fig. C3529)

C3529
17 At this point the shaft should drop straight down-
wards. The shaft seal can now be removed and replaced.
It can not be removed in any other way. (fig. C3530)

Shaft

C3530

2-38
 DRIVE MOTOR 2.11
Disassembly (cont’d)
18 Complete disassembled unit. (fig. C3531)

Complete disassembled unit.

2

C3531

2-39
 DRIVE MOTOR 2.11
Assembly
1 The re-assembly of the motor is done opposite of the
dissassembly. Support the housing and install the output
shaft and bearing assembly. (fig. C3532).

2
C3532
2 Install bearing retaining ring and tighten with Torx
drive to 7ft/lbs. (fig. C3533)

Install bearing
C3533

3 Alternate installation of brake disks, first putting in

the outer disk (golden color) and then the inner disk (sil-
ver color). (fig. 3534)

C3534

4 Install the piston after all of the disks have been

inserted. There will be air trapped, but this will escape
when the spring and cover are installed. (fig. C3535)

C3535

2-40
 DRIVE MOTOR 2.11

5 Install spring plate (fig. C3536)

2
C3536
6 Install brake cover and cross tighten all screws to
final torque specification of 65ft/lbs. (fig. C3537) Screws

C3537

7 Install Cardon shaft and gearwheel. (fig. C3538)

C3538

8 With the gearwheel mounted and the cardon shaft in

place, place the drive gear valley to valley with the gear-
wheel. Mount the channel plate (ensuring the drain holes
are aligned) and then valve drive it 15o counter clockwise
(one tooth). Then mount the valve housing and re-install
the bolts. (fig. C3539).
Incorrect timing will result in the motor operating in
reverse.

C3539

2-41
 DRIVE MOTOR 2.11
Assembly
9 Gear-roller stage of motor.
Timing is important to ensure oil pressure/flow enters the
correct chamber for proper drive/rotation. (fig. C3540)

2
C3540

10 When preparing for timing, marker valley to valley Front cover

in any location on shaft as shown (fig. C3541).

C3541

11 Install guide pins on gearwheel (3) and fix channel

plate onto gearwheer (fig. C3542)

C3542

12 Use securing ring and install onto grove on channel

plate (fig. C3543).

IMPORTANT
NOTE: The fibre plates are also called outer plates
due to the “teeth” outside of the plate.

C3543
2-42
 DRIVE MOTOR 2.11
Marker Guide

13 The timing is critical as the gearwheel valley cannot

be seen. Use a marker point as a guide to offest 1 tooth
counter-clockwise to the disk valve (fig. C3544).

2
C3544

14 In the valve housing, install the 6 springs in the

drilled holes (fig. C3545). Springs

C3545

15 Inspect the O-ring seals, and if needed, replace.

Install the balance plate and use guide pin for alignment
(fig. C3546).

C3546

16 Example of an incorrectly installed balance plate.

The guide pin becomes damaged and the balance plate is
not locked into position. This can cause it to spin and ren-
der the motor non-functional (fig. C3547).

C3547
2-43
 DRIVE MOTOR 2.11
17 With a balance plate incorrectly installed other prob-
lems such as a break in the valve housing may occur and
damage other hydraulic components (fig. C3548).

2
C3548

18 With the balance plate in the proper position and

tapped down to seat, apply some vaseline or grease to
prevent the spacer from falling out when installed onto
the motor (fig. C3549).

C3549

19 Since the motor has been disassembled, the guide

pins will locate ports in the offset position. To align with
the drain and brake ports, turn the section until correct
port alignment is made (fig. C3550).

C3550

20 With ports all aligned, install balance of screws and

tighten in a cross pattern, then final torque all bolts to 81
ft/lbs (fig. C3551).

C3551
2-44
 TORQUE CHART 2.12
NOTE: all torque specifications are in ft / lbs. (Multiply by 1.36 = N.m.)

Hydraulic Fittings
HOSE SIZE 37º JIC FITTINGS HOSE SIZE ORB FITTINGS
1/4
5/16
3/8
1/2
5/8
9 to 10
15 to 16
20 to 22
30 to 33
40 to 44
1/4
5/16
3/8
1/2
5/8
14 to 16
18 to 20
24 to 26
50 to 60
72 to 80
2
3/4 70 to 77 3/4 125 to 135
7/8 82 to 90 7/8 160 to 180
1 55 to 60 1 200 to 220
1 1/4 120 to 132 1 1/4 210 to 280
1 1/2 131 to 144 1 1/2 270 to 360
2 300 to 330
The following torque specifications are for steel ORB fittings into aluminum.
HOSE SIZE ORB FITTINGS HOSE SIZE ORB FITTINGS
1/4 5 to 7 3/4 40 to 45
5/16 8 to 10 7/8 50 to 55
3/8 10 to 12 1 90 to 99
1/2 21 to 24 1 1/4 80to 90
5/8 27 to 30

Tandem Pump Torque Motor

Description Qty. Specification Description Qty. Specification
Front Support 1 50 (+/- 2) Valve Housing 8 81 ft/lb
Rear Mounting 2 60 (+/- 2) Bearing Housing 8 65 ft/lb
Trunion Seal Carrier 4 20 (+/- 2) Bearing, Retaining Ring 8 bolts 7 ft/lb
Trunion Seal Cover 4 20 (+/- 2) Mounting 4 80ft/lb
Relief Valve 4 40 (+/- 10)
Charge Relief Cap 1 40 ~ 100
Tandem Section 4 40 (+/- 5)
Gear Pump 2 25 (+/- 2)

2-45
 CONVERSION CHART 2.13
CONVERSION FACTORS
Metric To U.S.
MULTIPLY BY TO OBTAIN

2 Area:

Force:
sq. meter
hectare

newton
newton
10.763 91
2.471 05

3.596 942
0.224 809
square foot
acre

ounce force
pound force

Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq.inch

bar 14.50385 lb/sq.inch

Temperature: degree C 1.8 x C + 32 degree F

Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
millimeter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid
litre 0.219 969 gallon (Imperial)

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

2-46
 CONVERSION CHART 2.13
CONVERSION FACTORS
U.S. To Metric
MULTIPLY BY TO OBTAIN

2
Area: sq. foot 0.092 903 square meter
acre 0.404 686 hectare

Force: ounce force 0.278 014 newton

pound force 4.448 222 newton

Length: inch 25.4 millimeter

foot 0.304 8 meter
mile 1.609 344 kilometer

Mass: pound 0.453 592 kilogram

ounce 28.35 gram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.5930276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq.in. 6.894 757 kilopascal

lbs/sq.in. 0.069 bar
lbs/sq.in. 0.070 303 kg/sq.cm

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter

Velocity: miles/hr. 1.609 344 kilometer/hr.

Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764 555 cubic meter
ounce (U.S. fluid) 29.573 53 milliliter
quart (U.S. liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (U.S.) 3.785 412 litre
gallons (Imperial) 4.546 092 litre

Volume/Time: gallon/min. 3.785 412 litre/min.

2-47