HYDRO-GEAR BDP-10L SERVICE AND REPAIR MANUAL Table of Contents – Page 1 of 1 INTRODUCTION/GENERAL DESCRIPTION: BDP-10L VARIABLE PUMP INTRODUCTION GENERAL DESCRIPTION BDP-10L VARIABLE PUMP: SUPPORT SYSTEM TRANSMISSION HYDRAULIC SUPPORT SYSTEM SAFETY PRECAUTIONS CONTROLS AND FEATURES: BDP-10L VARIABLE PUMP DIRECT DISPLACEMENT CONTROL CHARGE PUMPS BYPASS VALVE BDP-10L VARIABLE PUMP: START-UP & MAINTENANCE FLUIDS START-UP PROCEDURE MAINTENANCE TROUBLESHOOTNG CHART: BDP-10L VARIABLE PUMP BDP-10L VARIABLE PUMP: M
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Table of Contents Description Page Introduction ..................................................... 1 General Description......................................... 1 Support System............................................... 2 Controls & Features ........................................ 3 Start-up & Maintenance .................................. 4 Troubleshooting Chart..................................... 5 Minor Repair.................................................... 6 General .....................
Description General Introduction The purpose of this manual is to provide information The BDP pumps can be combined with motors and other useful in servicing the Bantam Duty Hydrostatic Pumps. remotely units. When used in this manner, these This manual includes unit and component description, units provide an infinitely variable speed range between troubleshooting,minorrepairprocedures,andmajor zero and maximum inboth forward and reverse modes of operation. repair procedures.
Transmission Hydraulic Support System The charge pump incorporated into theBDP-10L units Since either of the main hydraulic passages canbe supplies fluidto keep the closed loop charged, prevent- at high pressure, two (2) charge check valves are ingcavitationandprovidingcooling oil flowforthe usedtodirectmake-upfluidintothelowpressureside system. An inlet filter is required to insure that only of the closed loop.These check valvesa r e located in clean fluid enters the system.
Controls and Features Direct Displacement Control The direct-proportional displacement control (DDC) provides a simple method of control. Movementofthe swashplate control shaft produces proportional a swashplate movement and change in pump flow and/or direction. If difficulties are encountered with the control, inspect the connection of the control linkage to the swashplate control shaft to insure that the linkage is properly attached.
Start-up & Maintenance Fluids Fluids used with Hydro-Gear products beshould carefully selected with assistance from a reputable supplier. Typically, an API classification SG/CD engine oil is used with a viscosity range equivalent20W50. to Start the engine and run at the lowest possible RPM. Start-up Procedure With the bypass valve closed, slowly move the displacement controlin both the forward and reverse directions.
Troubleshooting Chart Symptom Vehicle will not attain normal maximum speed. Probable Cause Suggested Remedy Engine not operating at correct Speed. Repair engine governor. Control linkage damaged or binding. Repair control linkage. Bypass valve stuck partially open. Repair bypass valve. Charge check valve held open. (Problem in one directiononly) Vehicle will not move when vehicle Control linkage damaged or not connected. control is moved. Remove foreign material from valve.
Minor Repair General Fitting/Plug Torques Minor repairs maybe performed, following the proce- If any plugs are removed from the housing or end cap during servicing, they should be torqued as indicated in dures in this section, without voiding the unit warranty. the accompanying tables: Cleanlinessisa primary means of assuring satisfactory Item Torque lie on either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually CaseDrainFitting 15-20 ft. Ibs.
Note: Once the pump input shaft seal is removed, the out of pump block spring may push the shaft partially the housing.bo not attemptto pull the shaft out of the housing. Internal parts could move out of alignment or fall into the transmission, requiring major disassembly of theunit. Inspect the dealing area on the shaft for rust, wear or contamination. Polish the sealing area on the shaft if necessary. Install InputShaft Seal Lubricate the new seal with petroleum jelly.
I Bypass Valve Unscrew the, bypass valve from the end cap. NOTE: Some valveshavea 5/8" hexend while others have a cross hole. Inspect the valve and mating seat in the end cap for damage or foreign material. It is recommended that the O-ring andbackupring be replaced. Reinstall the bypass valve into the end cap. 7-Torque to 10 ft. lbs. BypassValve At Variations Charge Pump The charge pump rotation is determined by the orientation of the charge pump cover on the end cap.
Inspect the gerotor assembly, charge pump cover, and end cap for abnormal wear, damage or foreign material. Inspect the charge relief ball valve and spring. Inspect the charge relief valve seat in the end cap for damage or foreign material. Priorto installilng the charge pump, apply a small quantity of petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly Install the charge relief valve ball and spring. Install the charge pump gerotor assembly.
Major Repair General Theproceduresonthefollowingpagesareforthe complete disassembly and reassembly (Major Repair) of the BDP-10L variable pump. Again, cleanliness is primary a means of assuring satisfactory hydraulic unit life on either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually adequate.As with any precision equipment, all parts must be kept free of foreign materials and chemicals.
Remove the thrust bearing from the swashplate. Remove the pump swashplate from the housing. Remove the swashplate cradle bearings from the housing. Remove the slot guide block from the displacement control shaft. Remove Pump Cylinder Block Kit, Block Spring and Washer, Swashplate andCradle Bearings from Housing Remove the input shaft seal retaining ring. Carefully pull the input seal shaft out of the housing bore.
If the pump block spring retaining ring requires replacement, removeit from the pump shaft. Remove the displacement control shaft seal out of the housing. Care mustbe takenso a snot to damage the housing bore. Cylinder Block Kit Components Reconditioning and Replacement of Parts Afterdisassembly,all parts should thoroughly be cleaned in a suitable solvent. Replaceall O-rings, gaskets and shaft seals. is pressed into the end cap and The pump shaft bushing should not be removed.
If the block spring retaining ring was removed from the pump shaft, install a new retaining ring onto the shaft. (if used) Install a new inner bearing retaining ring onto the pump shaft. Press the bearing onto the shaft. Install the washer (if used) and a new outer bearing retaining ring. NOTE: Do not stretch ordeform the retaining ring. Install, the pump shaft and bearing assembly into the housing. Install InputShaft Install the bearing spacer washer.
Install the swashplate cradle bearings into the housing, making sure they are located on the cast-in pins in the housing. Install the slot guide blockonto the displacement control shaft. Install Cradle Bearings and Guide Block swashplate. Install the Swashplate into the housing. The slot on the swashplate must engage the guide block on the displacement control shaft.
Install the springs, piston washers and pistons into the With the pump swashplate in the "neutral" (0 angle) cylinder block. The pistons must move freely in their position and;he pump housing laying onits side, install bores. the pump cylinder blockkit onto the pump shaftin the housing. Check that the piston springs are centered inthe cylinder block bores. If necessary, position them with a small screwdriver. Install the two (2) aligning pins, and install a new end cap gasket onto the housing.
1 No. Description 1 HousingKit seal-Up 2 End Cap Jut End Cap No. Part No. 2513017 Description 17 Ring, Up 18 Shaft- cump Part No.
Variation Chart MODELNO. Shaft # BDP-10L-1 I I 2003020 I I I I BDP-10L-1 10 2003020 CHECK VALVEKITS BYPASS VALVE KIT 2513029 I 2513029 I Trunnion Opp.
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