Sitework Systems Products Dingo® TX 413 Compact Utility Loader Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
REVISIONS TX 413 SERVICE MANUAL Revision 000 . . . . . . . . . . . Revision 001 . . . . . . . . . . . ii 7/30/05 4/13/09 Rev.
TABLE OF CONTENTS TX 413 SERVICE MANUAL Safety Information General Information . . . . . . . . . . . . . . . . . . . . . . . . . . Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications General Specifications Dimensions . . . . Hydraulic System . . Electric System . . . Track System . . . Performance . . . . Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TX 413 SERVICE MANUAL Hydraulic System Hydrostatic Pump Reference Drawing . . . . . . . . . . . Valve Reference Drawings . . . . . . . . . . . . . . . Purging Air Procedures . . . . . . . . . . . . . . . . . Adjusting the Tracking of the Traction Control, Full Forward Position Adjusting the Traction Control Neutral Position . . . . . . . . Hydrostatic Pump (Right Drive) Removal . . . . . . . . . . Hydrostatic Pump Service . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TX 413 SERVICE MANUAL Hydraulic Lift Assembly cont. Loader Valve Disassembly and Assembly . . . Joystick Assembly Removal . . . . . . . . Joystick Assembly Installation . . . . . . . Spool Removal . . . . . . . . . . . . . Spool Assembly . . . . . . . . . . . . Power Beyond Sleeve-Port . . . . . . . . Main Relief Valve . . . . . . . . . . . . Work Port Relief . . . . . . . . . . . . Auxiliary Spool Valve Disassembly and Assembly Disassembly . . . . . . . . . . . .
TABLE OF CONTENTS TX 413 SERVICE MANUAL Attachments Auger Removal............................................................................................................................10-2 Auger Reassembly......................................................................................................................10-3 Auger Tooth and Fishtail Shank Removal...................................................................................10-3 Fishtail Shank Installation.........................
SAFETY INFORMATION TX 413 Service Manual Rev.
SAFETY INFORMATION General Information Avoid burns... This symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. Do not touch the engine, muffler, or other components which may increase in temperature during operation, while the unit is running or shortly after it has been running. This manual is intended as a service and repair manual only.
SAFETY INFORMATION Avoid modifications... Never alter or modify any part unless it is a factory approved procedure. Avoid unsafe operation... Always test the safety interlock system after making adjustments or repairs on the machine. Refer to the Electrical section in this manual for more information. Hydraulics Safety • Inspect all hydraulic line connectors and fittings. Make sure all hydraulic hoses and lines are in good condition before applying pressure to the system.
SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. 1-4 Rev.
SPECIFICATIONS TX 413 Service Manual Rev.
SPECIFICATIONS Special Tools • Hydraulic Flow & Pressure Tester (Hydro-Gear BDP) Bi-directional Flow Test Kit (P/N 70661) or equivalent • 15º/60º Offset Open End Wrench, 1/8" and 15/16" • Torque Wrenches - nominal torque ranges, plus one capable of 300 ft-lbs. (407 Nm) • Multimeter General Specifications Item Specification Engine Honda Model GX390 13 horsepower, 4-cycle, air cooled, single cylinder, overhead valves, 12 VDC solenoid shift starter, 10 amp alternator, and low oil shut down.
SPECIFICATIONS Hydraulic System: Item Specification Gear Pump Single section 6.9 gpm (26.12 liter/min) gear pump powers the loader and auxiliary hydraulic systems. Loader Valve Two-spool mono-block valve controls loader functions via a single lever joystick. The valve has a power beyond circuit which feeds the auxiliary circuit. Main Relief Setting: 2650 psi (182.71 bar) Work Port Reliefs: 2030 psi (140 bar) for the bucket curl and loader lower circuit.
SPECIFICATIONS Track System: Item Specification Track The tracks are Kevlar reinforced, endless rubber rings with 28 internal lugs. The outer tread on the tracks is a turf-friendly S-shaped pattern with pitched crosscuts. Track Width: 5.88 inches (14.9cm) Track Pitch: 3.45 inches (8.8cm) Drive Wheel The drive wheels are single-piece, austempered ductile iron, “squirrel cage” castings. Wheel Diameter: 11.63 inches (29.
SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. 2 These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m M10 X 1.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.25 Class 8.
SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.
SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
MAINTENANCE TX 413 Service Manual Rev.
MAINTENANCE (1) is located under the hood for the loader arm assembly (Fig. 002). Greasing the Traction Unit Grease all pivot joints every 8 operating hours and immediately after every washing. Grease Type: Lithium based NLGI2 1. Lower the loader arm and stop the engine. Remove the key from the ignition switch. 2. Clean the grease fittings with a rag. 3. Connect grease gun to each fitting and pump grease into the fittings until grease begins to ooze out of the bearings (approximately 3 pumps). 4.
MAINTENANCE (2) are located on the right side of the unit (Fig. 004). Figure 004 3. Remove the wheel bearing cap with seal (Figure 006). DSC-0769 Figure 006 DSC-0822 Maintaining the Road Wheels 1. Remove the tracks; refer to Track Removal, page 8-4. Note: Remove the tracks only when the inner wheels or the complete tray of wheels needs maintenance. 2. Remove the snap ring and cap from a road wheel (Fig. 005). Figure 005 TX 413 Service Manual 4.
MAINTENANCE 6. Place the greased road wheel cap and seal over the bolt head. 7. Secure the road wheel cap with the snap ring (Fig. 008). Hydraulic Reservoir Tank Location The hydraulic reservoir tank is located in the front of the TX 413 unit. Hydraulic Tank Capacity: 10 gallons (37.
MAINTENANCE 5. Remove the cap from the filler neck (Fig. 010). Replacing the Hydraulic Filter Change the hydraulic filter: After the first 8 operating hours. After every 200 operating hours. 1. Position traction unit on level surface. 2. Lower the loader arm, stop the engine, and remove the key. 3. Open the hood. IMPORTANT: Do not substitute an automotive oil filter or severe hydraulic system damage may result. 4. Remove the old filter (Fig. 012). Figure 010 DSC-1368 6.
MAINTENANCE 9. Start the engine, raise and lower the loader arm, then drive the unit forward and backward to purge air from the system and check for leaks. 6. Remove the hydraulic tank cap and dipstick (Figures 014 and 015). 10. Stop the engine, check the fluid level in the hydraulic tank (refer to Checking the Hydraulic Fluid, page xx ) and add fluid to raise the level to mark on dipstick. Do not over fill the tank. A 11. Close the hood.
MAINTENANCE 10. Replace the hydraulic oil filter. 11. Start the engine, remove the cylinder lock, raise and lower the loader arm, then drive the unit forward and backward to purge air from the system and check for leaks. Servicing the Engine, Air Cleaner Replacement, and Spark Plug Servicing See the Dingo TX 413 Operator's Manual. Or, for more details, see the Honda Engine Operator’s or Service Manuals. 12. Stop the engine. 13. Check the hydraulic fluid level and top it off if necessary.
MAINTENANCE Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure 8 hrs Grease the traction unit Check engine oil level Check for loose fasteners Inspect the tracks for damage or wear Change hydraulic filter after the initial 8-10 operating hours 25 hrs Check hydraulic oil Inspect hydraulic lines for leaks 50 hrs Clean the foam pre-filter with liquid soap and warm water Clean the paper air filter by lightly tapping on flat surface 100 hrs Change engine oil
ENGINE TX 413 Service Manual Rev.
ENGINE 4. Remove the drive belt; refer to Drive Belt Removal and Replacement, page 8-2. Introduction The engine removal and installation procedure is provided in this manual. Refer to the engine manufacturer's owner's and service manuals for maintenance intervals and service procedures. 5. Loosen the two set screws on the engine drive pulley (Fig. 019). Engine Removal 1. Start the unit and raise the loader arm assembly to the fully raised position.
ENGINE 7. Remove the bolt and nut securing the exhaust deflector to the left hand frame (Fig. 021). Figure 021 9. Remove the four bolts and nuts at the base of the front grille (Fig. 023). 8. Remove the two bolts and nuts on the backside of the exhaust deflector (Fig. 022). Figure 022 TX 413 Service Manual Figure 023 DSC-1090 DSC-1092 10. Remove the front grille with the exhaust deflector attached (Fig. 024). DSC-1091 Rev.
ENGINE 11. Remove the gas tank vent hose on the hydraulic oil filter bracket (Fig. 025). Figure 025 13. Remove the bolt and nut retaining the hose clamp for the oil reservoir vent hose and the clamp holding the fuel shut off valve (Fig. 027). DSC-1095 Figure 027 12. At the base of the fuel tank bracket, left side, remove the two bolts and nuts holding the bracket to the frame (Fig. 026).
ENGINE 15. Remove the fuel line clamp located at the electric fuel shut off valve (fuel line between shut off valve and carburetor (Fig. 029). 17. Remove the two bolts and nuts to the tank bracket on the right side (Fig. 031). Figure 031 Figure 029 DSC-1101 DSC-1099 18. Remove the fuel tank and tank bracket (Fig. 032). 16. Disconnect the wire terminals for the fuel shut off valve (Fig. 030).
ENGINE 19. Disconnect the charge coil wire, black to white (Fig. 033). Figure 033 21. Disconnect the oil switch, black to white wire (Fig. 035). Figure 035 DSC-1103 20. Disconnect the plug and jack connection for the charge coil leads to the rectifier (Fig. 034). DSC-1107 22. Disconnect the blue wire and two red wires on the starter assembly (Fig. 036). B A Figure 034 DSC-1105 Figure 036 A - Blue wire 4-6 Rev.
ENGINE 23. Disconnect the throttle cable clamp and the throttle cable from the top of the engine (Fig. 037). 25. Remove the two front engine mounting bolts and nuts (Fig. 039). B A Figure 037 A. Throttle Clamp Figure 039 DSC-1112 DSC-1114 B. Throttle Cable 26. Remove the two rear engine mounting bolts and nuts. 24. Remove the engine air cleaner cover. Disconnect the choke cable clamp and choke cable from the front of the engine (Fig. 038).
ENGINE 27. With an overhead hoist, raise the engine slightly and slide the engine forward and then up and off the frame of the unit (Fig. 041). Figure 041 2. Install the two rear engine mounting bolts and nuts. Note: Make sure the two ground wires are installed on the left rear bolt, with the star washer installed first. DO NOT TIGHTEN THE BOLTS AND NUTS. (Fig. 043) DSC-1118 Figure 043 Engine Installation DSC-1115 1. Lower engine to the frame (Fig. 042). 3.
ENGINE 9. Apply an anti-seize compound to the engine crankshaft and key. Apply a medium strength threadlocking material to the threads of the set screws and install the engine drive pulley. Using a straight edge, align the engine drive pulley to the lower hydrostatic pump pulley; with the engine bolts loose, you can move the engine to help align the pulley (Fig. 045). Choke Cable Installation 1.
ENGINE Throttle Cable Installation 1. Move the throttle control on the dash to full position, then back the throttle control so it is approximately 1/16" (1.6mm) away from the front edge of the slot (Fig. 049). 4. Connect the blue wire onto the spade terminal and the two red wires to the post on the starter assembly (Fig. 051). B A Figure 051 A - Blue wire Figure 049 B - Red wires DSC-1126 2.
ENGINE 6. Connect the plug and jack connection to the alternator wires to the rectifier (Fig. 053). Figure 053 8. Install the fuel tank and tank bracket on the frame (Fig. 055). DSC-1105 TX 413 Service Manual DSC-1102 9. Install two bolts and nuts located on the right side of the tank bracket and leave loose (Fig. 056). 7. Connect the magneto wire, black to white wire (Fig. 054). Figure 054 Figure 055 DSC-1103 Rev.
ENGINE 12. Install the bolt and nut retaining the hose clamp for the oil reservoir vent hose and the clamp holding the fuel shut off valve and tighten (Fig. 059). 10. Connect the wire terminals for the fuel shut off valve (Fig. 057). D C B A Figure 057 A - Green wire B - Yellow wire DSC-1100 C - Violet wire D - Pink wire Figure 059 13. Install the two bolts and nuts, left side, holding the fuel tank bracket to the frame and tighten (Fig. 060). 11.
ENGINE 15. Install the fuel tank vent hose on the oil filter bracket (Fig. 061). Figure 061 17. Install four bolts and washers located at the base of the front grille (Fig. 063). DSC-1095 16. Install the front grille with the exhaust deflector attached (Fig. 062). Figure 062 TX 413 Service Manual Figure 063 DSC-1129 18. Install the two bolts and nuts on the backside of the exhaust deflector (Fig. 064). DSC-1093 Rev.
ENGINE 19. Install bolt and nut located at the bottom of the exhaust deflector and tighten the bolt (Fig. 065). Then tighten the rest of the bolts in the front grille, the right side tank bracket, and on the exhaust deflector. Fuel Tank Removal 1. Start the unit, raise the lift arm to the fully raised position and install the hydraulic cylinder lock in the lift cylinder. Shut engine off. 2. Remove the rear cover and remove the negative battery cable. 3.
ENGINE 7. Remove the fuel line from the fuel tank fitting. With a wrench, turn the fuel tank fitting so it is pointing out toward the left side of the unit (Fig. 070). 5. Disconnect the fuel line located on fuel shut off valve that goes to the fuel tank (Fig. 068). Figure 068 DSC-1133 Figure 070 DSC-1137 6. Drain the fuel tank (Fig. 069). 8. Remove the fuel tank from the unit (Fig. 071). Figure 069 DSC-1134 Figure 071 TX 413 Service Manual Rev.
ENGINE 3. Remove the fuel fitting from the steel wire. Tape a new fuel fitting to the steel wire and pull the fitting through the fuel tank and out the bottom of the tank (Fig. 074). Bulkhead Fuel Fitting Replacement 1. Remove the nut and washer from the fuel fitting (Fig. 072). Figure 072 DSC-1140 2. Tape a piece of steel wire approximately 30" long to the fitting , then push the fitting into the tank, tilt the tank and feed the fuel fitting out the fill neck of the fuel tank (Fig. 073).
ENGINE 3. Install the fuel line on the fuel shut off valve and install the clamp (Fig. 078). Fuel Tank Installation 1. Install the fuel tank on the unit taking care not to damage the fuel fitting (Fig. 076). Figure 078 Figure 076 DSC-1139 2. Turn the fuel fitting toward the rear of the unit and tighten the fitting nut, then install the fuel line and clamp (Fig. 077). 4. Install the two fuel tank straps located on the top of the fuel tank and install the nuts and bolts and tighten (Fig. 079).
ENGINE 5. Install the vent hose on the oil filter bracket (Fig. 080). Figure 080 Starter Service Serial numbers 200000200 and higher have an opening for easier access to the starter (Fig. 081). DSC-1095 Figure 081 6. Install the positive battery cable, then the negative cable. 7. Install the rear cover. DSC-0583 Manual Shutoff This engine also has the manual fuel shut off on the carburetor (Fig. 082). 8. Start the unit and check for any fuel leaks.
ELECTRICAL SYSTEM PK PK BN GN R VIO + _ HOUR METER BK NOTE: SOME WIRE COLORS CHANGE AT REGULATOR CONNECTOR BK F2 GND W REG.
ELECTRICAL SYSTEM There are two primary current paths when the ignition switch is in the "START" position. (1) Current flows from the ignition switch to both the coil and contact terminals of the start relay. From the coil terminal of the start relay, current flows to the neutral detent (located on the Auxiliary Power Valve) to the contact terminal of the kill relay. Also, current flows to the engine starter.
ELECTRICAL SYSTEM 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87a. Apply +12 VDC to terminal 85. With terminal 86 still grounded, the relay should break and make continuity between terminals 30 and 87a as 12 VDC is applied and removed from the terminal (Fig. 085). Location The ignition switch is located on the top control panel (Fig. 087). Figure 087 Figure 085 xl relay DSC-0750 How It Works Detents inside the switch give it 3 positions: OFF, RUN, and START.
ELECTRICAL SYSTEM Auxiliary Power Neutral Switch Testing Purpose 1. Disconnect the switch from the wiring harness. Leave the switch in the Auxiliary Power Valve. 3. The normally closed ball type switch is used on the auxiliary power valve. This is a safety type switch to make sure the auxiliary power valve is in the neutral detent (Fig. 088). 2. Using a VOM multimeter (ohms setting) there should be continuity between the two wire terminals. 3.
ELECTRICAL SYSTEM Location 3. If not, check stator output. Using a multimeter set to AC volts, connect a probe to D and E terminal (grey wire). Start the unit and operate at full throttle. The AC voltage should be 27 volts or more. If not, the stator is bad. Stator resistance can also be checked - it should be 0.16 - 0.24 Ohms. If OK, proceed to step 4. The regulator-rectifier is located behind the rear cover, in back of the hoses (Fig. 091). 4. Shut the engine OFF.
ELECTRICAL SYSTEM Hour Meter Testing Purpose 1. Verify that 12 volts is present across the two terminals when the key is in the "RUN" position. Since the meter is polarized, it is important the positive wire is connected to the correct terminal (Fig. 118). The hour meter keeps track of how long the key has been in the "RUN" position. Also, the hour meter has a Maintenance Reminder Program. Icons will flash 3 hours before the service interval through 3 hours after the service interval.
ELECTRICAL SYSTEM Location Testing The neutral proximity switch is located behind the rear cover, under the dash, in front of the traction control lever (Fig. 096), and can be viewed and adjusted from under the hood. 1. Before electrically testing the switch, check the location of the switch and bolt, to make sure they are meeting in the sense zone on the switch. Both the switch and the bolt are adjustable and the air gap between them should be 1/8” to 1/4" (3.2 to 6.4mm). 2.
ELECTRICAL SYSTEM Fuel Solenoid or Shutoff Valve Testing Purpose 1. With the fuel solenoid connected to the wire harness, turn the ignition key to the "RUN" position. Verify there is 12 VDC at the connector with the pink wire. The fuel shutoff valve is located in-line between the gas tank and the engine carburetor. When the ignition switch is in the "OFF" position, fuel will not flow to the engine carburetor. When the ignition switch is in the "START" and "RUN" positions, the shutoff valve is open. 2.
ELECTRICAL SYSTEM Electrical Schematic Wiring Diagram PN 88-9830 X I S B Y A WIRE COLOR CODES OFF = no connections = B I A and X Y ON START = B I S BK – BN – BU – GN – GY – OR – BK/Y – Ignition switch terminal Locations viewed from back SW4 IGNITION SWITCH X I Y S B A BLACK BROWN BLUE GREEN GREY ORANGE BLACK/YELLOW PK – R – T – VIO – W – Y – W/BU – OPTIONAL HEADLIGHTS F3 VIO B BK A 10A PK PK BN GN R VIO + _ HOUR METER BK NOTE: SOME WIRE COLORS CHANGE AT REGULATOR CONNECTOR BK F2 GND
ELECTRICAL SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 5-10 Rev.
HYDRAULIC SYSTEM TX 413 Service Manual Rev.
HYDRAULIC SYSTEM Hydrostatic Pump Reference Drawing 1 5 Hydrostatic Pump (Left Drive) 1. Hydraulic Return Line to Reservoir Tank 2. Hydrostatic Pumps Case Drain Line to Reservoir Tank 3A. Right Drive Hydraulic Line 3B. Right Drive Hydraulic Line 4A. Left Drive Hydraulic Line 4B. Left Drive Hydraulic Line 5. Case Drain Hydraulic Line 6. Inlet Hydraulic Line (lower pump) 7.
HYDRAULIC SYSTEM Valve Reference Drawings Line “I” Line “2” Line “3” Line “H” Principal Hydraulic Lines Loader Arm Hydraulic Lines Line “A” Line “B” Line “C” Line “D” Line “E” Line “4” Line “1” TX 413 Service Manual Rev.
HYDRAULIC SYSTEM Purging Air Procedures Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system. These purge procedures should be implemented anytime a hydrostatic system or hydraulic lines has been opened to facilitate maintenance or any additional oil has been added to the system.
HYDRAULIC SYSTEM 4. If the traction unit veers right, loosen the left jam nut and adjust the tracking set screw on front of the traction control (Fig. 102). 4. Open the rear access cover (Fig. 103). C B A Figure 103 Figure 102 A. Left jam nut C. Reference Bar DSC-0778 fig 38.bmp B. Operator Handle 5. Repeat steps 1 through 4 until the traction unit drives straight in the full forward position.
HYDRAULIC SYSTEM 4. Loosen the two set screws located on the hydrostatic pump pulley and remove the pulley (Fig. 105). 6. Start the traction unit and set the engine throttle to 1/3 engine throttle speed. 7. If the left track moves, lengthen or shorten the right traction rod until the track stops moving. 8. If the right track moves, lengthen or shorten the left traction rod until the track stops moving. 9. Tighten the jam nuts. 10. Close the rear access cover. 11.
HYDRAULIC SYSTEM 6. Remove the upper end of the inlet hydraulic line at the T-fitting adapter, (page 6-2, Ref. 6), located on the lower hydrostatic pump (Fig. 107, top view). 8. Loosen and remove the hydraulic inlet line, (page 6-2, ref 7), located on the back side of the upper hydrostatic pump (Fig. 109). Figure 109 Figure 107 7. On the lower side of the T-fitting adapter, remove the hydraulic inlet line, (page 6-2, Ref. 7), from the lower hydrostatic pump that runs to the upper hydrostatic pump (Fig.
HYDRAULIC SYSTEM 10. Disconnect the hydraulic case drain line, (page 6-2, Ref. 2), from the bottom of the right drive hydrostatic pump, at the T-fitting that is connected to the reservoir tank (Fig. 111, rear view). Figure 111 12. Disconnect the two hydraulic lines to the wheel motor, (page 6-2, Ref. 3A and 3B), (Fig. 113). Note: It may be necessary to loosen the hydraulic lines at the wheel motors. 11. Disconnect the hydraulic case drain line from the upper hydrostatic pump, (page 6-2, Ref.
HYDRAULIC SYSTEM 14. Remove the Allen bolt, spacer, and nut from the pump lever assembly (Fig. 115). Figure 115 16. Carefully lower the hydrostatic pump down and maneuver under the hydraulic hoses and out of the backside of the unit (Fig. 117). DSC-0876 Figure 117 15. Remove the two bolts and nuts holding the hydrostatic pump to the frame (Fig. 116). DSC-0878 Hydrostatic Pump Service For hydrostatic pump service, refer to Hydro-Gear BDP-10 service manual (Toro P/N 492-4789).
HYDRAULIC SYSTEM 2. Maneuver the right drive hydrostatic pump under the hydraulic hoses and up to the opening in the frame. Secure the frame with two bolts and nuts. DO NOT tighten the bolts at this time (Fig. 118). 4. Connect and hand tighten the inlet hydraulic line from the T-fitting adapter (page 6-2, Ref. 7) from the right drive hydrostatic pump to the left drive hydrostatic pump (Fig. 120, top view and Fig 121). A Figure 118 DSC-0884 Figure 120 DSC-0885 A. Left Hand Drive Pump 3.
HYDRAULIC SYSTEM 5. Connect and hand tighten the case drain hydraulic line (page 6-2, Ref. 2) to the bottom of the T-fitting adapter, located on the bottom of the right drive hydrostatic pump (Fig. 122, rear view). 7. Connect and hand tighten the case drain hydraulic line (page 6-2, Ref. 6), to the 90° fitting located on the top of the left drive hydrostatic pump (page 6-2, Ref. 1) (Fig. 124). Figure 122 Figure 124 DSC-0887 6. Connect and hand tighten the case drain hydraulic line (page 6-2, Ref.
HYDRAULIC SYSTEM 10. Position the control handle so the Allen head bolt can be installed through the rod, linkage spacer, pump lever assembly, and a nut. Tighten the assembly and make sure the control handle is moving freely (Fig. 126). 12. Install drive belt; refer to the Drive Belt Installation section on page 8-3. 13. Install battery and battery cables. 14. Follow the Purging Air Procedures; refer to the Purging Air Procedures on page 6-4. 15. Check all of the hydraulic line connections for any leaks.
HYDRAULIC SYSTEM 4. Loosen the two set screws located on the hydrostatic pump pulley and remove pulley (Fig. 128). Figure 128 6. Disconnect the case drain hydraulic line (page 6-2, Ref 5), from the top of the left drive hydrostatic pump (Fig. 130). DSC-0891 Figure 130 DSC-0893 5. With a 1-1/8" offset open end wrench, remove both the left drive hydraulic motor lines (page 6-2, Ref. 4A and 4B), (Fig. 129). 7. Remove the inlet hydraulic line, (page 6-2, Ref.
HYDRAULIC SYSTEM 8. Position the control handle so you can install a 1/4" Allen wrench into the Allen head bolt retaining the rod linkage spacer to the pump lever assembly (Fig. 132). 10. Remove the two mounting bolts and nuts holding the left drive hydrostatic pump to the frame (Fig. 134). Figure 134 Figure 132 11. Lift the hydrostatic pump up and out of the unit (Fig. 135). 9. Remove the Allen bolt, spacer, and nut from the pump lever assembly (Fig. 133). A C B D Figure 135 Figure 133 A.
HYDRAULIC SYSTEM Hydrostatic Pump (Left Drive) Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 4. Connect the case drain hydraulic line to the top of the pump and hand tighten (page 6-2, Ref. 5) (Fig. 138). 1.
HYDRAULIC SYSTEM 9. Position the control handle so you can install the Allen head bolt through the rod end bearing, spacer, pump lever assembly, and a nut. Tighten the assembly and make sure the control handle is moving freely (Fig. 142). 6. Connect and tighten the top hydraulic line (page 6-2, Ref. 4A) to the wheel motor (Fig. 140). Figure 140 DSC-0906 Figure 142 DSC-0896 7. Recheck all of the fitting connections and tighten. 8.
HYDRAULIC SYSTEM 11. Install drive belt; refer to Drive Belt Installation section on page 8-3. Hydrostatic Pump (Left Drive) Hydraulic Fitting Orientation 12. Install battery and battery cables. A. Case Drain B. Inlet C. Bypass 13. Follow the Purging Air Procedures; refer to the Purging Air Procedures section on page 6-4. 14. Check all the hydraulic line connections for any leaks. D. Linkage Bracket E. Wheel Motor A E 15.
HYDRAULIC SYSTEM 2. Remove the pump lever assembly and traction clamp (Fig. 147). Figure 147 2. Remove the drive belt; refer to the Drive Belt Removal section on page 8-2, step 4 (Fig. 148). Figure 148 DSC-0882 For installation, reverse the order of removal (refer to Figures 146 and 147 shown above). Note: Do not interchange pump lever assemblies between hydrostatic pumps. DSC-0779 3. Loosen the two set screws on the gear pump pulley (Fig. 149).
HYDRAULIC SYSTEM 4. Disconnect and remove the hydraulic line going to the loader arm valve (Fig. 150). Figure 150 6. Loosen and remove the two mounting bolts and nuts that retain the gear pump to the frame. Once the pump mounting bolts are loosened and removed, the pump can be pulled away from the frame and the pulley can be removed from the shaft (Fig. 152). DSC-0911 5. Loosen the hose clamp and remove the hydraulic suction hose from the front of the gear pump and slide the hose off the fitting (Fig.
HYDRAULIC SYSTEM Hydraulic Gear Pump Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. When installing a new gear pump, make sure the hydraulic fittings are installed properly; refer to the Gear Pump Fittings section on page 6-21. 4. Apply a medium strength threadlocking material to the set screws and install in the gear pump pulley.
HYDRAULIC SYSTEM 6. Install the hose clamp on the hydraulic suction hose and tighten the clamp (Fig. 158). Gear Pump Hydraulic Fitting Orientation A B Figure 160 Figure 158 DSC-0912 7. Install the loader arm valve line and tighten (Fig. 159). A. Inlet DSC-0919 B. Outlet Gear Pump Disassembly and Assembly NOTE: Cleanliness is a primary means of assuring satisfactory life on repaired pumps. Thoroughly clean all exposed surfaces prior to any type of maintenance.
HYDRAULIC SYSTEM 3. Mark the outside gear pump, body, front cover, and rear cover, to make sure they assemble together the same way they were disassembled (Fig. 163). Gear Pump Disassembly 1. Seal Kit for gear pump assembly (Fig. 161). Figure 161 DSC-1461 Figure 163 2. Remove the snap ring and woodruff key from the input shaft (Fig. 162). A 6-22 4. Remove the four retaining bolts and washers (Fig. 164). B Figure 162 A. Snap ring DSC-1462 DSC-1471 with key Figure 164 B. Woodruff key Rev.
HYDRAULIC SYSTEM 5. Remove the rear cover (Fig. 165). Figure 165 7. Lift the body from the thrust plate (Fig. 167). DSC-1465 6. Remove seals from the body and thrust plate. With a marker, mark the thrust plate in relation to the pump body (Fig. 166). Figure 167 8. Remove and separate the rear thrust plate from drive shaft and driven gear (Fig. 168). Figure 168 Figure 166 TX 413 Service Manual DSC-1468 DSC-1469 DSC-1467 Rev.
HYDRAULIC SYSTEM 9. Remove the input shaft and gear (Fig. 169). Figure 169 11. With a marker, mark the thrust plate in relation to the front cover (Fig. 171). DSC-1472 Figure 171 DSC-1474 10. Remove the driven gear (Fig. 170). 12. Remove the thrust plate from the front cover (Fig. 172). Figure 170 DSC-1473 Figure 172 6-24 Rev.
HYDRAULIC SYSTEM 13 With a hammer and drift punch, remove the shaft seal from the front cover (Fig. 173). Figure 173 2. Install the snap ring on to hold the seal in place (Fig. 175). Figure 175 DSC-1477 Inspection: There should be no scratches or pits deep enough to catch the fingernail with any internal component. Scratches or pits that catch the fingernail are unacceptable and the gear pump must be replaced. DSC-1480 3. Lubricate and install a new seal with the groove of the seal facing up (Fig.
HYDRAULIC SYSTEM 6. Lubricate and install the drive shaft and gear (Fig. 179). 4. Lubricate and install the back-up ring in the groove of the seal (Fig. 177). Figure 177 Figure 179 DSC-1482 5. Install the thrust plate to the front cover (seals facing the front cover). DSC-1484 7. Lubricate and install the driven gear (Fig. 180). NOTE: Match up the alignment marks on the front cover and thrust plate (Fig. 178). Figure 180 Figure 178 6-26 DSC-1486 DSC-1483 Rev.
HYDRAULIC SYSTEM 8. Install the seal and the back-up ring following steps 3 and 4. 11. Install the body on the front cover, making sure the marks are aligned (Fig. 183). 9. Lubricate and install the thrust plate with the seals facing the rear cover and the alignment mark facing you (Fig. 181). Figure 183 Figure 181 DSC-1489 DSC-1491 12. Install the rear cover on the body; again, make sure the marks are aligned (Fig. 184). 10. Lubricate and install new seals on the both ends of the body (Fig. 182).
HYDRAULIC SYSTEM 13. Install the four bolts and washers. Tighten the bolts on a criss-cross pattern; torque to 33 ft-lbs. (45 Nm) (Fig. 185). Figure 185 DSC-1493 Wheel Motors Wheel motor removal and replacement is covered in the Drive System section of this manual, page 8-16. For wheel motor service, refer to the Parker-Ross TF wheel motor service manual (Toro P/N 492-4753). 6-28 Rev.
HYDRAULIC SYSTEM Hydraulic Schematic Diagram TX 413 Service Manual Rev.
HYDRAULIC SYSTEM Hydraulic Schematic Diagram 6-30 Rev.
HYDRAULIC SYSTEM TX 413 Service Manual Rev.
HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 6-32 Rev.
HYDRAULIC LIFT ASSEMBLY TX 413 Service Manual Rev.
HYDRAULIC LIFT ASSEMBLY Loader Valve Removal Note: Cleanliness is a key factor in the successful repair of the hydraulic lift assemblies. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning of all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 3. (Fig. 187, Ref.
HYDRAULIC LIFT ASSEMBLY 7. (Fig. 191, Ref. H) Remove the hydraulic drain line from the hydraulic lift valve that goes to the T fitting on the oil filter base. 5. (Fig. 189, Ref. D) Remove the second hydraulic tilt cylinder hose from the fitting at the hydraulic lift valve. Figure 189 DSC-0929 TX 413 Service Manual DSC-0933 8. (Fig. 192, Ref. I) Remove the hydraulic line from the hydraulic lift valve that goes to the auxiliary valve. 6. (Fig. 190 Ref.
HYDRAULIC LIFT ASSEMBLY 9. Remove two of the three retaining bolts that mount the hydraulic lift valve to the frame. There are three access holes located in the frame (Fig. 193). Loader Valve Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Install the valve and align the mounting holes. Install the three bolts and tighten (Fig. 195). Figure 193 DSC-0936 10.
HYDRAULIC LIFT ASSEMBLY 3. (Fig. 197, Ref. H) Install the hydraulic drain line from the T-fitting on the oil filter base to the hydraulic lift valve and tighten. 5. (Fig. 199, Ref. D) Install the hydraulic hose to the fitting on the hydraulic lift valve and tighten. Figure 199 Figure 197 6. (Fig. 200, Ref. C) Install the hydraulic hose to the fitting on the hydraulic lift valve and tighten. 4. (Fig. 198, Ref. E) Install the hydraulic hose from the gear pump to the hydraulic lift valve and tighten.
HYDRAULIC LIFT ASSEMBLY 7. (Fig. 201, Ref. B) Install the hydraulic hose to the fitting on the hydraulic lift valve and tighten. Figure 201 Auxiliary Valve Removal The hose connections at the auxiliary valve on units with serial numbers 240000100 - 240000200 are close to each other. To obtain enough room to remove the upper hose, the lower hose and fitting needs to be removed (Fig. 203). DSC-0927 8. (Fig. 202, Ref. A) Install the hydraulic hose to the fitting on the hydraulic lift valve and tighten.
HYDRAULIC LIFT ASSEMBLY Note: Cleanliness is a key factor in a successful repair of any valve system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 3.
HYDRAULIC LIFT ASSEMBLY 5. (Fig. 208, Ref. 1) Remove the rear hydraulic hose from the fitting on the auxiliary valve 7. (Fig. 210, Ref. 3) Remove the hydraulic return line from the front of the auxiliary valve. Note: It will be helpful to tag the hydraulic hoses to ease reassembly. Figure 210 Figure 208 DSC-0944 6. (Fig. 209, Ref. 2) Remove the hydraulic line coming from the loader arm valve.
HYDRAULIC LIFT ASSEMBLY 8. Remove the two retaining bolts and nuts holding the auxiliary valve to the frame and lower the valve (Fig. 212). Auxiliary Valve Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Serial number range from 240000100 through 240000200, (Fig. 214, Ref. 4) Install the upper hydraulic hose to the fitting on the auxiliary valve. Figure 212 DSC-0948 9. (Fig. 213, Ref.
HYDRAULIC LIFT ASSEMBLY 2. Install the two retaining bolts and nuts holding the auxiliary valve to the frame (Fig. 216). Figure 216 DSC-0948 3. (Fig. 217, Ref. 3) Install the hydraulic return line to the auxiliary valve. Figure 217 7-10 4. (Fig. 218, Ref. 2) Install the hydraulic line from the loader valve to the auxiliary valve. Figure 218 DSC-0945 5. (Fig. 219, Ref. 1) Install the lower hydraulic hose to the fitting on the auxiliary valve. DSC-0946 Rev.
HYDRAULIC LIFT ASSEMBLY 8. Turn the torsion spring clockwise and hold. Slide the auxiliary lever over the control shaft and hook the spring end over the auxiliary lever (Fig. 222). 6. Connect the neutral ball switch at the harness connector (Fig. 220). Figure 220 DSC-0942 Figure 222 DSC-0941 7. Slide the torsion spring over the control shaft, with the large hook end of the spring facing down (Fig. 221). 9. Install the washer and retention nut on the top of the lever and tighten the nut (Fig. 223).
HYDRAULIC LIFT ASSEMBLY Hydraulic Tilt Cylinder Removal Units with serial numbers from 240000100 through 240000200 have a fixed, non-swivel fitting (Fig. 224). Note: Cleanliness is a key factor in a successful repair of any hydraulic cylinder. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
HYDRAULIC LIFT ASSEMBLY 2. Remove the two hose clamps located under the loader arm assembly (Fig. 227). Figure 227 4. Place a jack stand under the quick attachment assembly. Extend cylinder to ease the removal of ram end pivot pin (Fig. 229). DSC-0968 Figure 229 3. Remove the cylinder lock, install a 4 x 4 block of wood under the front lift cylinder pin and lower the loader arm assembly so it rests on the block of wood and frame (Fig. 228). Figure 228 5. Remove the rear cover.
HYDRAULIC LIFT ASSEMBLY 6. Place an oil drain pan under the control valve hoses (Fig. 231, Ref. D). Remove the hydraulic hose from the fitting on the lift valve. Figure 233 Figure 231 Note: DSC-0970 Use paint or other marking method to mark both ends of one hose and its valve and cylinder fitting (Fig. 232 and Fig. 233). Note: It may help to remove the “Line D” hydraulic valve fitting before attempting to remove the next hydraulic hose. 7. (Fig. 234, Ref.
HYDRAULIC LIFT ASSEMBLY 8. Pull the two hydraulic hoses from the rear of the unit out the side, under the loader arm (Fig. 235). Figure 235 10. Remove the shoulder bolt that holds the pivot pin on the ram end of the hydraulic cylinder (Fig. 237). DSC-0975 Figure 237 9. Pull the two hydraulic hoses through the front opening of the loader arm (Fig. 236). Figure 236 11. Using a drift punch and a hammer, drive the pivot pin out of the ram end of the hydraulic tilt cylinder (Fig. 238).
HYDRAULIC LIFT ASSEMBLY 12. Remove the bolt and nut on the pivot pin located on the barrel end of the hydraulic tilt cylinder (Fig. 239). 14. Remove the hydraulic hoses from the tilt cylinder (Fig. 241). Figure 241 Figure 239 DSC-0986 DSC-0983 15. For information on repairing the Tilt Hydraulic Cylinder, refer to the Hydraulic Cylinder Service section of this manual, page 7-40. 13.
HYDRAULIC LIFT ASSEMBLY 3. Install the bolt and nut and torque to 16 + 2 ft-lbs. (21.7 + 2.7 Nm) (Fig. 244). 1. Install hydraulic hoses to the tilt cylinder and tighten the hoses, making sure to connect marked hose to marked fitting. For reference purposes, hose “D” in Fig. 231 connects to the ram end of the tilt cylinder (Fig. 242). Figure 244 Figure 242 DSC-1017A 2.
HYDRAULIC LIFT ASSEMBLY 5. Install shoulder bolt and torque to 16 + 2 ft-lbs. (21.7 + 2.7 Nm) (Fig. 246). Apply grease to the grease fitting with a grease gun. 7. Feed the hydraulic hoses toward the back of the loader arm. Make sure the hoses are routed to the inside of the auxiliary hoses that go to the quick couplers. 8. Route the two hydraulic hoses up from the tilt cylinder through the upper frame hole (Fig. 248). Figure 246 DSC-0990 6.
HYDRAULIC LIFT ASSEMBLY 10. Connect hydraulic hose (Fig. 250, Ref. C) to the hydraulic lift valve fitting and tighten. Figure 250 12. Using a cable tie, tie the two hydraulic tilt hoses, 3" (7.62cm) from the barrel end fitting (Fig. 252). Figure 252 DSC-0971 11. Connect the hydraulic hose, Ref. D, to the hydraulic lift valve fitting and tighten (Fig. 251). DSC-0995 13. Start the unit and raise the loader arm assembly to the full raised position.
HYDRAULIC LIFT ASSEMBLY 14. Install the two hose clamps located under the loader arm assembly. Note: Units with a serial number of 240000201 and higher have a revised hydraulic hose clamp. It is easier to install this clamp by using a crescent wrench to pry down on the bracket to install the bolt and nut (Fig. 256). Note: The clamps have wide and narrow channels. Make sure the wide channel goes to the outside of the loader arm, retaining the two hydraulic hoses for the auxiliary quick couplers (Fig. 254).
HYDRAULIC LIFT ASSEMBLY 15. Install cable tie strap around all four hydraulic hoses, approximately 8" (20.32cm) to the right of the rear clamp (Fig. 258). Figure 258 Hydraulic Lift Cylinder Removal Note: Units with serial numbers from 240000100 through 240000200 have a fixed fitting at the mounting end of the lift cylinder. You will need to hold the hydraulic line with a wrench and turn the cylinder until the hydraulic line is disconnected from the cylinder (Fig. 260). DSC-1075 16.
HYDRAULIC LIFT ASSEMBLY Note: Cleanliness is a key factor in a successful repair of any hydraulic cylinder. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 2. Start the unit and raise the loader arm.
HYDRAULIC LIFT ASSEMBLY 4. Remove the hydraulic hose from the fitting on the hydraulic lift valve (Fig. 265). Figure 265 6. Remove the bolt and nut on the pivot pin located at the barrel end of the hydraulic cylinder (Fig. 267). DSC-1025 Figure 267 DSC-0997 5. Remove the bolt and nut on the pivot pin located at the ram end of the hydraulic lift cylinder (Fig. 266). 7. Remove the hydraulic hose from the fitting on the hydraulic lift valve (Fig. 268).
HYDRAULIC LIFT ASSEMBLY 10. Remove the pivot pin on the barrel end of the hydraulic cylinder by using a drift punch and hammer, tapping the pin out from the inside of the frame, toward the outside (this is a top view of the barrel end of the pivot pin) (Fig. 271). 8. Mark the hydraulic hose and fitting at the ram end of the hydraulic lift cylinder (Fig. 269). Note: It may be necessary to remove the hydraulic return line to the reservoir to get more clearance to remove the pivot pin.
HYDRAULIC LIFT ASSEMBLY 12. Remove the hydraulic lift cylinder from the frame of the unit (Fig. 273). Hydraulic Lift Cylinder Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings and seals should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Install the hydraulic hoses to the lift cylinder. Replace the cable ties to the hydraulic hose and hydraulic lift cylinder and tighten the hoses (Fig. 275). Figure 273 DSC-1016 13.
HYDRAULIC LIFT ASSEMBLY 3. Make sure the two hydraulic lift hoses are routed under the other four hydraulic hoses; 2 hydraulic hoses for the auxiliary couplers and two for the hydraulic tilt cylinder (Fig. 277). 5. Apply a small amount of grease to the pivot pin on the barrel end of the lift cylinder and slide the pin through, then align the bolt hole. Use a socket or pipe to tap the pivot pin in, so damage to the grease fitting does not occur (Fig. 279). Install bolt and nut, then tighten.
HYDRAULIC LIFT ASSEMBLY 7. Connect the next hydraulic hose to the hydraulic fitting on the lift valve and tighten (Fig. 281). Figure 281 Units, with serial numbers 240000201 and higher will have a clamp and hoses routed as shown in Fig. 283. DSC-1025 Figure 283 8. Units, with serial numbers 240000100 through 240000200 will have a clamp and hoses routed as shown in Fig. 282. Proper hose placement through the clamp (Fig. 284). A. B. C. D. E. F.
HYDRAULIC LIFT ASSEMBLY 9. Install cable tie strap around all four hydraulic hoses, approximately 8" (20.32cm) to the right of the rear clamp (Fig. 285). Loader Arm Assembly Removal 1. Remove the rear cover and belt cover. 2. Raise the loader arm assembly to the highest position and install the cyclinder lock in the hydraulic lift cylinder (Fig. 286). Figure 285 DSC-1075 10. Start the unit and raise the loader arm. Remove the jack stand.
HYDRAULIC LIFT ASSEMBLY Note: Units with serial numbers from 240000100 through 240000200 have a fixed fitting (Fig. 290). 4. Remove the bolt and nut retaining the pivot pin on the ram end of the lift cylinder (Fig. 288). Figure 288 DSC-1043 Figure 290 5. Remove the cylinder lock and lower lift arm. Support the loader arm assembly with an overhead lift (Fig. 289). Figure 289 TX 413 Service Manual DSC-1029 Note: Units with serial numbers from 240000201 and higher have a swivel fitting (Fig. 291).
HYDRAULIC LIFT ASSEMBLY 6. At the loader arm valve, mark the tilt cylinder hydraulic hose and fitting with paint or marker. Remove the hydraulic hose from the fitting (Fig. 292). Figure 292 8. Cut the cable ties around the hydraulic hoses. Remove the hydraulic hose clamp located in the back at the lower left corner and cut the cable tie holding the two hoses together (Fig. 294). Figure 294 DSC-1045 Proper hose placement through the clamp (Fig. 295). 7.
HYDRAULIC LIFT ASSEMBLY 9. Pull the two tilt cylinder hydraulic hoses from the rear of the unit out the side under the loader arm (Fig. 296). 11. Remove the hydraulic hose from the male quick coupler fitting. Pull the hydraulic hose down and out of the loader arm assembly. 12. Remove the hydraulic hose from the female quick coupler fitting (Fig. 298). Pull the hydraulic hose down and out of the loader arm assembly. Figure 296 DSC-0975 10.
HYDRAULIC LIFT ASSEMBLY 16. With a hammer and a long pipe, tap the pivot pin out of the loader arm assembly (Fig. 302). 14. Remove the two vent hoses, located above the oil filter bracket. The top vent is for the fuel tank (A) and the bottom vent is for the hydraulic reservoir tank (B) (Fig. 300). A B Figure 300 Figure 302 DSC-1058 DSC-1064 17. Lift the loader arm assembly from the unit (Fig. 303). 15. Remove the bolt and nut at pivot pin for the loader arm assembly (Fig. 301).
HYDRAULIC LIFT ASSEMBLY Loader Arm Assembly Installation 1. Route the tilt cylinder hoses through the opening of the frame (Fig. 304). 3. Use a drift punch in the first hole to align the hole for the bolt. Install bolt and nut and tighten to 16 + 2 ft-lbs. (21.7 + 2.7 Nm) (Figure 306). Note: Make sure the hoses are routed to the inside of the auxiliary hoses that go to the quick coupler. Figure 306 Figure 304 DSC-1061 DSC-1063 4. Install the two vent hoses, located above the oil filter bracket.
HYDRAULIC LIFT ASSEMBLY 5. Route the auxiliary hose through the loader arm assembly and connect it to the female quick coupler fitting and tighten (Fig. 308). Figure 308 7. Grease the pivot pin for ram end of the hydraulic lift cylinder and install on the loader arm (Fig. 310). DSC-1054 Figure 310 DSC-1066 6. Route the other auxiliary hydraulic hose, (the one that is marked when removed), and connect it to the male quick coupler fitting and tighten (Fig. 309). 8.
HYDRAULIC LIFT ASSEMBLY Note: Prior to connecting the hydraulic lines, the o-rings and seals should be replaced with new ones and lightly lubricated with petroleum jelly. 12. Start engine and raise the loader arm assembly to the fully raised position. Install the cylinder lock in the hydraulic lift cylinder and shut engine off (Fig. 314). 10. Connect hydraulic hose to the hydraulic lift valve fitting and tighten (Fig. 312). Figure 314 Figure 312 DSC-1041 DSC-1047 13.
HYDRAULIC LIFT ASSEMBLY 14. Install a cable tie around all four hydraulic hoses, about 3" (7.6cm) from the rear hose clamp in the loader arm assembly (Fig. 316). 16. Before installing the clamp, route the hoses through the clamp, refer to Fig. 317. Install the hose clamp, located on the lower left corner. Note: Units with a serial number of 240000001 through 240000200 will have the clamp shown in Fig. 318. Figure 316 DSC-1071 15.
HYDRAULIC LIFT ASSEMBLY 17. Install a cable tie around the four hydraulic hoses that go to the hydraulic lift valve. The cable tie should be approximately 8" (20.3cm) away from the hose clamp (Fig. 320). Figure 320 Quick Attachment Assembly Removal 1. Start engine and tilt the cylinder to lower the quick attachment assembly so it is laying flat on the ground (Fig. 321). DSC-1075 18. Start the unit and remove the cylinder lock assembly.
HYDRAULIC LIFT ASSEMBLY 3. Tap the pivot pin out of the ram end of the tilt cylinder using a hammer and drift punch (Fig. 323). Figure 323 5. Remove the right and left shoulder bolt retaining the pivot pins located on both sides of the quick attachment assembly. Remove both pivot pins (Fig. 325). DSC-1079 Figure 325 4. Support the tilt cylinder and remove the pivot pin (Fig. 324). Figure 324 6. Slide the quick attachment assembly away from the loader arms (Fig. 326).
HYDRAULIC LIFT ASSEMBLY Loader Arm Bushing Replacement 1. With attach plate removed, raise the loader arm assembly up to the highest position and install the cylinder lock in the hydraulic lift cylinder. Shut the engine off. 2. With a drift punch and hammer, tap the bushing out of the loader arm assembly; there are two bushings per pivot pin (Fig. 327). 4. Start the engine and raise the loader arm assembly to the fully raised position.
HYDRAULIC LIFT ASSEMBLY 4. Grease the pivot pin for the ram end of the cylinder and install the pivot pin. Torque the shoulder bolt to 16 + 2 ft-lbs. (21.7 + 2.7 Nm) (Fig. 331). Figure 331 Hydraulic Cylinder, Lift and Tilt, Disassembly This section covers the disassembly and assembly on both the Hydraulic Lift Cylinder and the Hydraulic Tilt Cylinder. Both cylinders are similar in design; however, the removal of the heads of the cylinder are different and will require different spanner wrenches (Fig.
HYDRAULIC LIFT ASSEMBLY Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90° to the pin rotation axis (Fig. 333). 4. Rotate counter-clockwise until the retaining ring is completely removed (Fig. 334). Figure 334 Figure 333 DSC-1329 DSC-1335 5. Pull out on the rod to remove the piston and head assembly from barrel (Fig. 335).
HYDRAULIC LIFT ASSEMBLY Inspection INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5 inch long (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unaccept-able.
HYDRAULIC LIFT ASSEMBLY 1. Visually inspect for material defects and contamination. All seals and O-rings must be replaced with new parts (Head Assembly, Fig. 337, and Piston Assembly, Fig. 338). A C B A. Wiper B. U-Cup C. Head E D Figure 337 2. Lubricate the head and all seals with 10W-30 oil prior to installation. Using round-nose pliers, twist the dual lip u-cup seal into a "C" shape and allow it to snap into the groove (Fig. 339). DSC-1348 D. Static Back-up E.
HYDRAULIC LIFT ASSEMBLY 4. Install the Static Back-Up ring around the groove in the head (Fig. 341). 6. For easiest installation, warm Bi-directional Piston Seal (Teflon seal) in 120° to 150° F (48.9° to 65.6°C) 10W-30 oil. Lubricate the piston and all components with oil. Stretch the 0-ring Loader Seal into the groove in the piston. 7. Verify that the o-ring is not pinched or twisted. 8.
HYDRAULIC LIFT ASSEMBLY 11. Lubricate the ID of the head and install on the rod (Fig. 346). 9. Spread the Wear Ring into a "C" shape only enough to fit over the outside of the piston and snap it into its groove (Fig. 344). Figure 346 Figure 344 12. Lubricate the ID of the piston and install on the rod (Fig. 347). 10. Install tape around the threads on the rod and install the PRS Static O-ring onto the rod and remove tape (Fig. 345).
HYDRAULIC LIFT ASSEMBLY 15. Turn head into tube until the retaining ring hole is aligned with the milled slot opening. Install the hook end of the retaining ring into retaining ring hole in the head (Fig. 350). 13. Install the lock nut on the rod (Fig. 348) and torque to: tilt cylinder lock nut 175 - 200 ft-lbs. (237.3 271.2 Nm) lift cylinder lock nut 250 - 300 ft lbs. (339 406.7 Nm) Figure 350 Figure 348 DSC-1364 16. With a spanner wrench, rotate the head clockwise.
HYDRAULIC LIFT ASSEMBLY Loader Valve Disassembly and Assembly 1. Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination (Fig. 352). 1. Remove tie cable around the rubber bellows and remove the joystick assembly (Fig. 354). Wipe excess grease from the joystick. D A E B B C F Figure 352 A. Power beyond valve B. Work port relief C. Spring Cap Figure 354 DSC-1381 DSC-1377 2.
HYDRAULIC LIFT ASSEMBLY 5. Remove the pivot for the lift and tilt operation. Remove the nut holding the joystick joint (Fig. 358). 3. Pictured below (Fig. 356) are the joystick joints: A. Tilt Cylinder operation B. Loader Lift Cylinder operation C. Pivot for Lift and Tilt operation B A C Figure 358 Figure 356 6. Turn the loader lift joystick joint and remove two hex head screws, then remove the joystick pivot (Fig. 359). 4.
HYDRAULIC LIFT ASSEMBLY Joystick Assembly Installation 1. Install the joystick pivot with two hex head screws (Fig. 360). 3. Slide the end on the joystick joint onto the joystick pin for the tilt cylinder (Fig. 362). Figure 362 Figure 360 DSC-1728 4. Install the articulated holder with 3 hex head screws and lock washers torque to 17.7 ft.-lbs. (24 Nm) (Fig. 363). 2. Install the nut holding the joystick joint to the pivot for the lift and tilt operation (Fig. 361).
HYDRAULIC LIFT ASSEMBLY 5. Lubricate all of the articulated parts inside the mechanical joystick area with synthetic base grease grade NLGI2 (Fig. 364). 7. Install the lift/tilt handle (Fig. 366). Figure 366 Figure 364 DSC-1436 DSC-1434 Spool Removal 6. Install the rubber bellows over the base plate and install the tie strap in the groove of the rubber bellows (Fig. 365). Figure 365 Note: To disassemble and assemble the valve, it is best to hold the valve in a bench vise. 1.
HYDRAULIC LIFT ASSEMBLY 2. Remove the 3 hex head screws and spring lock washers and remove the articulated holder (Fig. 368). 4. Turn the loader lift joystick joint and remove the nut retaining it to the lift spool (Fig. 370). Figure 370 Figure 368 3. Slide the rod end off the joystick pin and remove the pin (Fig. 369). 5. Remove the two hex head retaining screws that retain the joystick pivot (Fig. 371). Figure 371 Figure 369 TX 413 Service Manual DSC-1397 DSC-1382 DSC-1398 DSC-1726 Rev.
HYDRAULIC LIFT ASSEMBLY 8. Using a drift punch to hold the top end of the spool, remove the detent spring assembly from the bottom of the spool (Fig. 374). 6. Remove two hex head retaining screws that retain the joystick base plate (Fig. 372). Figure 372 DSC-1399 Figure 374 7. Turn the valve assembly over. Remove the two hex head retaining screws securing each spring cap and remove (Fig. 373). Figure 373 9.
HYDRAULIC LIFT ASSEMBLY 10. Turn the valve in the vise sideways. Remove the tilt spool by twisting and pulling the spool out the top of the valve (Fig. 376). Note: Visually inspect spool outside surfaces for scratches. Deep scratches are unacceptable and the spool needs to be replaced. Scratches that are deep enough to catch the fingernail are also unacceptable, and the spool needs to be replaced. Before replacing the spool, clean and inspect the inner bore for damage.
HYDRAULIC LIFT ASSEMBLY Spool Assembly 12. Using a tool with a 90° angle, (for example, a snap ring pliers with 90° tips) remove both the spool valve seals located at the top of the valve (Fig. 379). Replace all seals and o-rings with new parts. Lubricate the valve, o-rings, and spool with 10W-30 oil prior to installation (Fig. 381). A B I Figure 379 C D E G F H C DSC-1411 Figure 381 A. B. C. D. E. 13.
HYDRAULIC LIFT ASSEMBLY 2. Lubricate and install the spool valve seals in the top of the valve (Fig. 383). Note: The thin wall of the seal goes into the valve body first. 4. Lubricate and install the lift spool in the right port of the valve, twist and push gently, so you do not damage the o-ring (Fig. 385). Figure 385 Figure 383 DSC-1416 3. Lubricate the tilt spool. Install the spool in the left port of the valve; twist and push gently, so you do not damage the o-ring (Fig. 384).
HYDRAULIC LIFT ASSEMBLY 6. Install the detent spring assembly and torque to 5 ft-lbs. (6.8 Nm). Lubricate the spring with synthetic base grease grade NLGI2 (Fig. 387). Figure 387 8. Rotate the valve in the bench vise. Install gasket and joystick base plate with two cap screws, torque to 7 ft.lbs. (9.5 Nm) (Fig. 389). DSC-1420 7. Install spool caps over the detent and spring valve. Torque the cap screws to 5 ft. lbs. (6.8 Nm) (Fig. 388). Figure 388 7-56 Figure 389 DSC-1423 9.
HYDRAULIC LIFT ASSEMBLY 10. Apply a medium strength threadlocking material to the threads of the loader lift joystick joint, and install the retaining nut to the lift spool. Torque the nut to 31 ft-lbs. (42 Nm) (Fig. 391). 12. Install the end rod on the joystick pin (Fig. 393). Figure 393 Figure 391 DSC-1430 DSC-1428 13. Install the articulated holder with 3 cap screws and torque to 18 ft-lbs. (24.4 Nm) (Fig. 394). 11.
HYDRAULIC LIFT ASSEMBLY 16. Install the lift/tilt handle (Fig. 397). 14. Lubricate all articulated parts inside the mechanical joystick area with synthetic base grease grade NLGI2 (Fig. 395). Figure 397 Figure 395 DSC-1436 DSC-1434 Power Beyond Sleeve-Port 15. Install the rubber bellows over the base plate and install the tie strap in the groove of the rubber bellows (Fig. 396). This sleeve seals off the return oil port and directs the hydraulic oil to the auxiliary valve (Fig. 398).
HYDRAULIC LIFT ASSEMBLY Main Relief Valve Work Port Relief Pressure relief is designed to prevent internal fluid pressure from rising above a pre-determined maximum pressure (Fig. 399). The work relief ports relieve the fluid spikes when the Lift and Tilt Cylinders are being actuated (Fig 401 and Fig. 402). These ports are non-adjustable. Port relief setting is 2030 psi (140 bar). Figure 399 DSC-1438 Figure 401 The relief valve is used to adjust to the specified system pressure (2650 psi or 182.
HYDRAULIC LIFT ASSEMBLY 2. Remove the spring cap by removing the two hex head cap screws (Fig. 405). Auxiliary Valve Disassembly and Assembly Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination (Fig. 403). A E B B F G C D Figure 405 Figure 403 A. B. C. D. Operator lever Inlet Detent Return spring cap DSC-1443 E. Rubber bellows F. Return G. Safety switch port DSC-1445 3.
HYDRAULIC LIFT ASSEMBLY 4. Remove the bottom neutral switch block by removing the two hex cap screws (Fig. 407). inner bore for damage. Check the condition of the o-rings particularly for metallic particles embedded in the o-ring surface. Damage to o-ring grooves, particularly on the sealing surface, is unacceptable. In the event that an unacceptable condition occurs, the valve needs to be replaced. 6. Remove the two o-rings located at each end of the valve.
HYDRAULIC LIFT ASSEMBLY 8. Remove the two o-rings located at each end of the neutral switch block (Fig. 411). Figure 411 2. Lubricate and carefully install the spool, from the bottom of the valve (Fig. 413). DSC-1453 Assembly Figure 413 DSC-1455 3. Install the neutral switch block with two hex head screws, torque to 5 ft-lbs. (6.8 Nm) (Fig. 414). Note: Replace all seals and o-rings with new parts. Lubricate the valve, o-rings, and spool with 10W-30 oil prior to installation. 1.
HYDRAULIC LIFT ASSEMBLY 4. Install the spool spring with a hex head screw, torque to 5 ft-lbs. (6.8 Nm) (Fig. 415). 6. Lubricate the cavity of the top lever assembly with a synthetic base grease grade NLGI2. Install the lever assembly and gasket. Torque the hex head screws to 5 ft-lbs. (6.8 Nm) (Fig. 417). Note: Lubricate the spring with synthetic base grease grade NLGI2. Figure 415 DSC-1457 Figure 417 DSC-1460 5. Install the spring cap and torque the hex head screws to 5 ft-lbs. (6.8 Nm) (Fig. 416).
HYDRAULIC LIFT ASSEMBLY THIS PAGE INTENTIONALLY LEFT BLANK. 7-64 Rev.
DRIVE SYSTEM TX 413 Service Manual Rev.
DRIVE SYSTEM 4. Remove the two fasteners holding the pulley cover and remove cover (Fig. 420). Drive Belt Removal 1. Shut engine "OFF", apply parking brake, and remove ignition key. 2. Remove belt cover knob and remove the belt cover (Fig. 418). Figure 420 Figure 418 DSC-0777 DSC-0779 5. Using a 12” (30.5cm) crow foot pry bar, insert the end of the crow foot between the idler bracket tab and the idler pivot shaft (Fig. 421). 3. Disconnect the two rear latches and remove the rear cover (Fig. 419).
DRIVE SYSTEM 6. Pry down with the pry bar to remove tension and remove the belt from the engine drive pulley (Fig. 422). Figure 422 Drive Belt Installation 1. Start by taking the belt and feeding it through the rear of the unit, around the gear pump pulley and then around both the lower and upper hydraulic pump pulleys (Fig. 424). DSC-0788 Figure 424 7. Remove the belt around the upper and lower hydraulic pump pulleys, and around the gear pump pulley. Slide the belt out the rear of the unit (Fig. 423).
DRIVE SYSTEM 3. Check belt routing, (Fig. 426). Start unit to make sure the belt is operating properly. Figure 426 2. Remove the bolt and nut securing the tensioner bolt (Fig. 428). Figure 428 106-9514 decal DSC-0793 3. Using a 1/2” drive socket ratchet, release the drive tension by turning the tensioner bolt clockwise until the tensioning nut contacts the tensioner bolt head. Push the tension wheel toward the rear of the unit (Fig. 429 and Fig 430). 4.
DRIVE SYSTEM 4. Begin removing the track at the top of the tension wheel, lifting up on the the track removing any slack from the bottom (Fig. 431). 6. Use a pry bar to help assist in removal of the track (Fig. 433). Figure 433 Figure 431 5. Start working the track off the front tension wheel while rotating the track forward (Fig. 432). 7. Remove the track off the rear drive wheel (Fig. 434). Figure 434 Figure 432 TX 413 Service Manual DSC-0798 DSC-0795 DSC-0801 DSC-0796 Rev.
DRIVE SYSTEM Tensioner Wheel Bearing Replacement 1. Remove tensioner arm assembly out of the frame (Fig. 435). Figure 435 3. Support the tensioner wheel so there is a space under it for bearing removal. Using a hammer, drive the upper bearing down to create a gap between spacer and bearing, then use a drift punch to hammer the lower bearing out. The spacer will fall out when bearing is removed. Turn the tensioner wheel over and drive out the other bearing.
DRIVE SYSTEM 1. Press the first bearing in so far that the outer bearing race is flush with the center hub. Turn the tensioner wheel over and install the spacer centered on the inner race (tensioner wheel bolt can be used to keep the spacer centered to the bearing inner race) and press the second bearing in until the spacer is held in tight between the bearings. 2. Reassemble the tensioner wheel to the tensioner arm.
DRIVE SYSTEM 4. Install compression spring and the bolt tensioner with tensioning nut. Track Guide Alignment Alignment Tool – P/N 110-0069 (Fig. 444) Note: Make sure the tensioning nut is contacting the bolt tensioner (Fig. 442). A B C D Figure 442 A. Tensioning nut B. Compression spring Figure 444 DSC-0624 DSC-0815 1. Insert the notched end of the alignment tool into the drive wheel spacer (Fig. 445). C. Tensioning bolt D. Tension Arm 5. Install the tensioner assembly into the frame (Fig.
DRIVE SYSTEM 2. Secure the end with the pin (Fig. 446). Figure 446 4. Tighten and torque the 4 track guide mounting bolts to 75 ft lbs (102 Nm) (Fig. 448). DSC-0628 Figure 448 3. Rotate the tool and move the track guide as necessary until the tool fits into the track guide channel. Secure the end of the tool with a strap (Fig. 447). DSC-0631 5. Remove the alignment tool. Track Installation 1. Engage the lugs on the track between the spacers on the drive sprocket (Fig. 449).
DRIVE SYSTEM 2. Push the track under and between the road wheels. Starting at the bottom of the tension wheel, install the track around the wheel by rotating the track rearward while pushing the lugs into the wheel (Fig. 450). 1. = 2-1/2 inches (6.35cm) B A Figure 452 A. Tension nut Figure 450 B. Tensioner Arm DSC-0796 3. Turn the tensioning screw counter-clockwise, (Fig. 451), until the distance between the tension nut and the back of the tensioner arm is 2-1/2 inches (6.35cm) (Fig. 452). 4.
DRIVE SYSTEM Track Guide Removal 5. Lower the track guide from the frame (Fig. 456). 1. Raise and securely support the side of the unit to be worked on so that the track guide is far enough off the ground to remove from the unit. 2. Remove the track, refer to "Track Removal" on page 8-4. 3. Install a hydraulic floor jack and 6" (15.24cm) wide board long enough to fit under the track guide (Fig. 454).
DRIVE SYSTEM 2. Remove wheel bearing cap with seal (Fig. 458). Figure 458 4. Remove the road wheel from the track guide (Fig. 460). DSC-0822 Figure 460 3. With a ratchet and socket, remove bolt retaining the road wheel (Fig. 459). Figure 459 5. Press bearing out from the seal side, pressing on the inner race of the bearing (Fig. 461). DSC-0823 Figure 461 8-12 DSC-0824 Rev.
DRIVE SYSTEM 6. Using a drift punch and hammer, tap out the seal (Fig. 462). Figure 462 2. Pressing on the outer race, press bearing in until it seats against the inner shoulder of the road wheel (Fig. 464). DSC-0828 Figure 464 Installation of Road Wheel Bearing and Road Wheel Assembly DSC-0830 3. Apply grease around the bearing before installing the seal (Fig. 465). 1. The raised portion of the bearing should be installed toward the seal side (Fig. 463).
DRIVE SYSTEM 4. Align seal so the lip is facing the bearing (Fig. 466). Figure 466 6. Install the road wheel on the track guide and torque bolt to 150 ft-lbs. (203 Nm) (Fig. 468). DSC-0832 5. Press seal in until it is flush with the inner hub of the road wheel (Fig. 467). Figure 467 8-14 Figure 468 DSC-0824 7. Fill the cap with grease and install the wheel gasket (Fig. 469). DSC-0833 Rev.
DRIVE SYSTEM 8. Secure the road wheel cap with the snap ring (Fig. 470). Figure 470 Note: DSC-0821 Track Guide Installation 1. With a hydraulic floor jack and a board to support the track guide, raise the track guide up to the frame (Fig. 471). Figure 471 The track guide end with a step is mounted toward the drive wheel (Fig. 472). Figure 472 DSC-0619 2. Install the four bolts that hold the track guide to the frame. Torque the bolts to 75 + 8 ft-lbs. (102 + 11 Nm) (Fig. 473).
DRIVE SYSTEM 4. Remove the track; refer to the Track Removal section, page 8-4. Wheel Motor Removal Note: This procedure can be used for the Left or Right Wheel Motor 1. Lift and securely support the unit so that the track is far enough off the ground to remove the wheel motor. 5. Remove cotter key from the motor shaft (Fig. 475). 2. Remove rear cover. 3. Disconnect the negative battery cable and then the positive cable; remove the battery. Slide an oil drain pan under the wheel motor (Fig. 474).
DRIVE SYSTEM 9. Using an off-set open-end wrench, remove both hydraulic line nuts from the fittings located on the top of the wheel motor (Fig. 479). 7. Using a wheel puller, remove the drive wheel (Fig. 477). Figure 477 DSC-0839 Figure 479 8. Loosen the hydraulic line nuts located at the hydrostatic pump (Fig. 478). DSC-0842 10. Remove both hydraulic fittings located at the top of the wheel motor (Fig. 480). NOTE: Remove the belt cover for easier access to the right hand hydraulic fitting.
DRIVE SYSTEM 11. Install a hydraulic floor jack under the wheel motor. Remove the 4 wheel motor mounting bolts (Fig. 481). Figure 481 Wheel Motor Installation 1. Position the wheel motor on a hydraulic floor jack with the hydraulic line ports facing up. Slide the wheel motor under the frame and raise into the frame opening. Apply medium strength threadlocking material to the mounting bolts and torque the bolts to 75 + 8 ft-lbs. (102 + 11 Nm) (Fig. 483). DSC-0843 12.
DRIVE SYSTEM 3. Install the hydraulic lines to the hydraulic fittings on top of the wheel motors and tighten (Fig. 485). 5. Clean the motor shaft with a degreaser to make sure there is no grease or dirt. Note: Do not use grease or anti-seize compound on the shaft. Install the drive wheel on the shaft, aligning the keyway (Fig. 487). Figure 485 DSC-0842 4. Tighten the hydraulic lines that connect to the hydrostatic pumps (Fig. 486). Figure 487 DSC-0849 6. Install the nut on the shaft.
DRIVE SYSTEM Note: Self-locking nut with thread-locking material may be used with some model years. This self-locking nut needs to be replaced whenever it is removed from the wheel motor shaft (Fig. 488). Figure 488 Traction Control Handle Assembly Removal 1. Remove the rear cover. 2. Remove the bolt and nut retaining the control handle assembly to the drive rod assembly (Fig. 489). DSC-0852 Figure 489 DSC-1247 7. Install track; refer the Track Installation, page 8-8. 8.
DRIVE SYSTEM 4. Disconnect the left side linkage rod by removing the bolt, spacer, and nut from the rod end bearing (Fig. 491). Figure 491 6. Turn the traction control assembly clockwise and remove the bushings, flat washers, and spring washers from the control support assembly (Fig. 493). DSC-1263 Figure 493 5. Remove four bolts and nuts that retain the bushings, located on each side of the control support assembly (Fig. 492). Figure 492 7.
DRIVE SYSTEM 8. Tilt the top of the control assembly forward and slide the assembly down and out of the control handle and then out of the unit (Fig. 495). Traction Control Handle Assembly Installation 1. Install traction control assembly, tilting the top of the control assembly forward so the control handle can be installed onto the drive rod assembly; do not install the bolt and nut. 2. Install flat washer, spring washer, washer, and then the bushing on each end of the control support assembly (Fig.
DRIVE SYSTEM 4. Install the left side rod linkage with a bolt through the bearing rod end, spacer, through the drive rod assembly and install the nut and tighten (Fig. 499). 6. Insert the bolt and nut into the traction control handle assembly and through the drive rod assembly. Note: The control handle assembly is slotted, so you need to align the assembly before tightening the bolt and nut (Fig. 501). Figure 499 DSC-1263 5.
DRIVE SYSTEM Brake Assembly Removal 1. Remove the rear cover. Disconnect the battery negative cable and then the positive cable. Remove the battery. Remove the battery bracket. 4. Remove the two bolts and nuts that hold the cable brackets to the brake bars (Fig. 504). 2. Disconnect brake cable by removing the bolt and nut that holds the brake cable end to the brake shaft assembly (Fig. 502). Figure 504 Figure 502 DSC-1265 DSC-1268 5.
DRIVE SYSTEM 6. Slide the left brake bar out of the frame (Fig. 506). Figure 506 8. Clamp the right side cable bracket in a vise. Using a tool to hook into the spring, pull back the spring enough to reach the set screw in the tube guide (Fig. 508). DSC-1271 Figure 508 DSC-1274 7. Remove the spring assembly and cable (Fig. 507). 9. Loosen the set screw on tube guide. Carefully compress the spring and slide the cable end from the slot in the cable bracket and remove (Fig. 509).
DRIVE SYSTEM 10. Loosen the set screw on the tube guide on the left side and remove the brake cable from the cable bracket (Fig. 510). Figure 510 12. Measure a piece of rope approximately 20" (50.8cm) long and equip it with a handle. Feed the rope through the two brake springs. Tie the rope to the end of the brake cable and pull the cable through the brake springs (Fig. 512). DSC-1277 Figure 512 11.
DRIVE SYSTEM 14. Remove the end of the rope, by cutting it. Slide the brake springs back and install the tube guide and tighten the set screw (Fig. 514). Figure 514 2. Slide the brake bar through the bracket on the frame, with the brake cable pulled to the front of the bracket (Fig. 516). Figure 516 DSC-1285 DSC-1287 Note: Serial #200000201 and higher will have an extra hole drilled to hold brake “OFF” manually. Brake Assembly Installation 1.
DRIVE SYSTEM 4. Install bolt and nut through the right side cable bracket and the bar bracket (Fig. 518). Figure 518 6. Install the brake cable through the bracket on the left side of the frame (Fig. 520). 5. Tighten the bolt and nut on the right and left cable brackets (Fig. 519). Figure 519 8-28 Figure 520 DSC-1289 DSC-1291 7. Attach the brake cable with a bolt and nut to the brake shaft assembly (Fig. 521). DSC-1290 Rev.
DRIVE SYSTEM 8. Brake Adjustment - Ensure the brake engages and disengages freely. The brake bars should both move in and out of the frame. When disengaged, the brake bar should not protrude more than 1/2" (12.7mm) out of the frame (Fig. 522). Figure 522 Idler Assembly Removal 1. Raise engine cover and remove the belt cover. 2. Use a pry bar to relieve idler tension and remove the drive belt (Fig. 524).
DRIVE SYSTEM 4. Remove the retaining ring on the end of the idler arm (Fig. 526). Figure 526 Figure 528 DSC-1295 1. Install idler pulley by first installing the spacer between the idler arm and idler pulley, bolt, washer and nut. Tighten bolt and nut to 27 - 33 ft-lbs. (36.6 - 44.7 Nm) (Fig. 529). DSC-1297 Figure 529 8-30 DSC-1298 Idler Assembly Installation 5. Remove the idler arm and torsion spring (Fig. 527). Figure 527 6.
DRIVE SYSTEM 2. Install idler arm. First, install the torsion spring on the pivot shaft and then install the idler arm (Fig. 530). 4. Apply medium strength threadlocking material to the threads of the set screws for the engine drive pulley. Apply anti-seize compound to the engine crankshaft and key. Install the engine drive pulley. 5. With a straight edge, align the engine drive pulley to the bottom hydrostatic pump pulley and tighten the engine set screws (Fig. 532). Figure 530 DSC-1300 3.
DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 8-32 Rev.
TESTING TX 413 Service Manual Rev.
TESTING Introduction Fitting sizes and test hose configurations are also shown (Fig. 535, 536, 537, 538 and 539). Due to the many types and manufacturers of test equipment, the test hoses and fittings needed will vary. Refer to the connection information at each hydraulic test location. Hoses being used for pressure and flow testing must exceed maximum system flow and pressure and must be compatible with the type of fluid in the hydraulic system (Fig. 533). A.
TESTING C. Couplers Coupler End – 7/8”-14 UNF-2B O-ring Seal (Fig. 537). Coupler Adaptor Kit 106-7695. Converts the 3/4” coupler to the 3/8” coupler (Fig. 539). A B Figure 537 DSC-0580 Figure 539 DSC-0585 A. P/N 100-4701 - Female coupler B. P/N 104-6134 - Male coupler Test Gauge – 3/4”-16 – 37° Female (Fig. 538). Test hoses: Figure 538 TX 413 Service Manual Diameter Length PSI Rated -8 3' 5000 DSC-0577 Rev.
TESTING TX 413 Hydraulic Testing The TX 413 hydraulic system utilizes a single gear pump to flow oil for all hydraulic components of the unit. The TX 413 hydraulic system can be separated into three circuits; loader, auxiliary and drive systems. Each is an open circuit system which allows oil to be flowing when the valves and the hydrostatic pumps are in the neutral position. The drive system includes the two hydrostatic pumps and wheel motors.
TESTING Test 1 - System Pressure Testing Test 2 - System Flow Testing This test checks the system pressure for both the auxiliary and loader circuits. Components involved in this test are Gear Pump, Loader Valve, Power Beyond Valve at Loader Valve, Auxiliary Valve, auxiliary couplers and hoses. This test will verify that pressure is or is not the reason for the problem in the hydraulic circuit. Depending on test results, Test 5 may need to be performed to determine system problem.
TESTING Test 3 - Flow Test Gear Pump to Loader Valve This test measures the flow output of the gear pump. Components involved are flow meter, suction hose and pump. This test will verify if the pump, pump pulley, or belt is at fault if flow does not meet specification. If flow meets specification the loader valve, auxiliary valve, steel line, hose or couplers may be at fault. Perform test 4. Test 3 - Flow Test at the Gear Pump to the Loader Valve 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
TESTING 11. If flow does meet specification, look for restriction of a hydraulic line from outlet of loader valve to couplers. If no restrictions are found then repair or replace auxiliary valve and/or couplers. Repeat. 12. Replace o-rings and reinstall hydraulic line from loader valve to auxiliary valve and tighten. 13. Check hydraulic fluid and add as needed. 14. Start unit and check for leaks. 15. Remove drain pans. 16. Release park brake. 17. Shut engine off.
TESTING Hydrostatic Testing Procedures Hydrostatic Pump Flow Testing Raise the unit and get both tracks off the ground. Use jack stands to support the unit (Fig. 545). WARNING Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground. To prevent possible injury to the servicing technician and/or bystanders, ensure the vehicle is properly secured. WARNING Do not attempt any adjustments with the engine running.
TESTING Left Drive System Flow Test 1. Lift and support the unit so tracks are 3 to 4" (7.6 to 10.2cm) off the ground. 3. Connect the flow tester to the two hydraulic fittings on the hydrostatic pump (Fig. 549). 2. Disconnect the two output hydraulic lines to the wheel motor with a 1-1/8" offset wrench (Fig. 547). Note: Before removing nuts from the hydraulic fittings, place a piece of tape around both hydraulic lines, so the nut will not slide down the hydraulic line.
TESTING 4. Start the engine and bring the engine speed up to full throttle. 6. Turn the restriction valve until you read 300 psi (21 bar) (Fig. 552). 5. Move the traction control in the left direction, in full forward motion (Fig. 551). Operate without any load for approximately 2 minutes; this allows the system oil temperature to rise. Figure 552 DSC-2934 7. At 300 psi (21 bar), note gpm reading (Fig. 553). Figure 551 DSC-2933 Note: The gpm reading can vary between left and right hydrostatic pumps.
TESTING 8. Then turn the restriction valve to 1100 psi (76 bar) (Fig. 554). Right Drive System Flow Test 1. Lift and support the unit so tracks are 3 to 4" (7.6 to 10.2cm) off the ground. 2. Disconnect the two hydraulic output lines with a 1-1/8" offset wrench to the wheel motor (Fig. 555). Figure 554 DSC-2942 9. At 1100 psi (76 bar) note gpm reading. Figure 555 Example: • 300 psi (21 bar) reading • 1100 psi (76 bar) reading 8 gpm (30 l/min) 1st reading 6.5 gpm (24.6 l/min) 2nd reading 1.5 gpm (5.
TESTING Note: Before performing this test, make sure the bypass valve, located on the front side of the lower pump, is closed (Fig. 557, top view). Note: Raising the system oil temperature will make a difference in the readings you receive. To complete the test accurately, the oil temperature must be near system operating temperatures. Suggested temperature range 160° - 210° F (71.1° 98.9° C). 6. Turn the restriction valve until you read 300 psi (21 bar) (Fig. 559). A Figure 557 B DSC-2943 4.
TESTING 8. Then turn the restriction valve to 1100 psi (76 bar) (Fig. 560). Figure 560 DSC-2942 9. At 1100 psi (76 bar), note the gpm reading. Example: • 300 psi (21 bar) reading • 1100 psi (76 bar) reading 8 gpm (30 l/min) 1st reading 6.5 gpm (24.6 l/min) 2nd reading 1.5 gpm (5.6 l/min) (the difference) Subtract the first gpm reading from the second gpm reading. This will determine your "flow droop". Note: The acceptable gpm "flow droop" or (difference) is 1.5 gpm (5.6 l/min).
TESTING THIS PAGE INTENTIONALLY LEFT BLANK. 9-14 Rev.
ATTACHMENTS TX 413 Service Manual Rev.
ATTACHMENTS Auger Removal 3. Stop the engine. 1. To remove the auger bit from the auger shaft, set the assembly down in its storage location (Fig. 001). 4. Remove the bolt and nut securing the auger bit or extension to the auger shaft (Fig. 003). Fig 001 CLR DSC-0220 Fig 003 CLR DSC-0217 5. Start the engine and back the traction unit away from the auger bit (Fig. 004). 2. While lowering the arms, drive slowly backwards until the auger is horizontal (Fig. 002).
ATTACHMENTS Auger Reassembly 2. Stop the engine. Reassemble in reverse order. 3. Remove teeth from auger bit by loosening nuts on the carriage bolts enough for the teeth to slide out (Fig. 006). Auger Tooth and Fishtail Shank Removal 1. While lowering the arms, drive slowly backwards until the auger assembly is horizontal (Fig. 005). Fig 005 CLR DSC-0221 Repeat on other lock nuts that hold gauge and wisdom teeth (Fig. 007). CLR DSC-0213 TX 413 Service Manual Fig 006 Rev.
ATTACHMENTS 4. Remove the screw and lock nut securing the fishtail shank to the auger bit (Fig. 008). Fig 008 CLR DSC-0224 5. The fishtail shank can be difficult to remove because it is being held in by dirt and debris – you may need to pry the fishtail shank away from the auger bit (Fig. 009 and Fig. 010). 10-4 Fig 009 CLR DSC-0226 Fishtail Shank Reinstallation 1. Reinstall the fishtail shank and torque nut and bolt to 16 + 2 ft-lbs. (22 + 3 Nm) (Fig. 011).
ATTACHMENTS Auger Tooth Replacement 1. Replace the new teeth in their correct location on the auger bit. Torque the lock nuts to 88 + 12 ft-lbs. (119 + 16 Nm) (Fig. 012). 3. The wisdom tooth is installed next to the gauge tooth on the inside edge closest to the auger shaft (Fig. 014). Note: It is good practice when replacing teeth to also replace the carriage bolts and nuts. Fig 014 CLR DSC-0382 4. Torque nuts to 150 + 15 ft-lbs. (203 + 20 Nm).
ATTACHMENTS Install dust caps over the ends (Fig. 016). Fig 016 3. Place a drain pan under hydraulic fittings to catch hydraulic oil in the lines. Then using a 15/16” wrench on the hydraulic line fitting and a 3/4” open end wrench to hold the motor fitting, disconnect hydraulic lines from the hydraulic motor (Fig. 018). CLR DSC-0103 2. Mark the hydraulic hose fitting and motor fitting to identify their location when reinstalling (Fig. 017).
ATTACHMENTS Removing the Hydraulic Motor 3. Lift the hydraulic motor from the auger housing (Fig. 022). 1. Using a 3/8” hex wrench remove the four hex head screws from the hydraulic motor (Fig. 020). Fig 020 Fig 022 CLR DSC-0108 CLR DSC-0112 4. Discard the o-ring from the hydraulic motor and replace it with a new one (Fig. 023). 2. Using a pry bar, gently break the seal between the hydraulic motor and the auger housing (Fig. 021).
ATTACHMENTS Note: Make sure you retain the motor shaft key (Fig. 024). Fig 024 CLR DSC-0110 Fig 026 CLR DSC-0115 3. Using 7/8” round stock to prevent the auger shaft from turning, remove the bearing nut using a breaker bar to loosen the nut (Fig. 027). Shaft Removal 1. Using a flat screwdriver, pry the 2 bearing lock washer tangs out of the notches on the bearing nut. 2. Using the TOR 6002 spanner socket, align the tabs of the socket with the notches on the bearing nut (Fig. 025 and Fig.
ATTACHMENTS Nut removed (four notches) (Fig. 028). 5. Raise the loader arms so the auger shaft clears the surface area it is resting on. 6. Rotate the auger housing up until you can slide a 1/2” x 2-3/4” bolt into the hole on the cradle arm to lock the auger housing in place (Fig. 030). Fig 028 CLR DSC-0122 4. Using two pairs of needle nose pliers, remove the bearing lockwasher (Fig. 029). Note: Do not reuse. Discard and replace with new lockwasher.
ATTACHMENTS 8. Using a 1/8” hex wrench, remove the three hex head screws from the bearing protector plate (Fig. 032). Remove the plate to access the 2 bearings and spacer. 10. Using a hammer and punch, go around the circumference of the bearing to drive the first bearing out. With the bearing removed, the spacer will slide out (Fig. 034 and Fig. 035). Fig 032 CLR DSC-0130 Fig 034 CLR DSC-0132 9. Remove the 1/2” x 2-3/4” bolt securing the auger housing to the cradle.
ATTACHMENTS 11. Reposition the auger housing so the shaft end faces down. Use a bearing driver or a hammer and punch to remove the second bearing from the housing (Fig. 036). Remove Power Head from Frame Assembly 1. From the operator’s position, mark the pivot plates with R for right and L for left before disassembly. 2. The auger housing has a right and left side and should be marked accordingly before disassembly. 3.
ATTACHMENTS 4. While supporting the auger housing, remove the pivot plate on one side from the frame assembly. The auger housing can now be set aside (Fig. 038). Fig 038 PICT-8710 Fig 040 CLR DSC-0155 Reassemble Power Head into Frame Assembly 5. Now remove the three pivot plate bolts from the other side and remove the pivot plate (Fig. 039). B 6. Remove the stop pad from the frame assembly (Fig. 040). 1. Install the stop pad on the frame assembly (Fig. 041). D C A A.
ATTACHMENTS 2. Install one of the pivot plates and 3 bolts and nuts to the frame assembly (Fig. 042 and Fig. 043). 3. Insert the auger housing into the previously installed pivot plate (Fig. 044). Fig 042 PICT-8704 Fig 044 PICT-8709 4. Insert the other pivot plate on the auger housing (Fig. 045). Fig 043 PICT-8703 TX 413 Service Manual Rev.
ATTACHMENTS 5. Install the 3 bolts and nuts to secure the pivot plate to the frame assembly (Fig. 046). Reassemble Auger Power Head 1. With the auger housing shaft facing up, use a bearing driver or press to install bearing. The bearing is seated when the surface is flush with the auger housing (Fig. 048 and Fig. 049). Fig 046 PICT-8712 6. Torque the six pivot plate bolts to 210 + 21 ft-lbs. (284.7 + 28.5 Nm) (Fig. 047).
ATTACHMENTS 4. Replace the three hex head screws on the protector plate and torque to 38 + 7 in-lbs. (4.3 + .79 Nm) (Fig. 052). 2. Reposition the auger housing so the shaft end is facing down and install spacer (Fig. 050). Fig 050 CLR DSC-0140 3. Keep the auger housing in its current position and install the second bearing with a press or bearing driver until it is fully seated. Note: When the bearing is seated there should be minimal play in the spacer.
ATTACHMENTS 6. Remove any dirt or debris from the auger shaft and slide it into the auger housing (Fig. 054). 8. Align the inner tab of the lock washer with the slot on the auger shaft (Fig. 056). Fig 054 CLR DSC-0161 7. Remove the 1/2” x 2-3/4” bolt securing the auger housing. Rotate the shaft down and lower arm. Insert the new bearing lockwasher onto the auger shaft. Make sure the tangs are facing out towards the bearing nut (Fig. 055). 10-16 Fig 055 Fig 056 CLR DSC-0165 9.
ATTACHMENTS 12. Once the torque value has been reached, if the lockwasher tangs do not line up with the notches on the bearing nut, continue to tighten the bearing nut until two tangs from the bearing lockwasher line up with the notches in the bearing nut (Fig. 060). 10. Install the bearing nut onto shaft with the chamfer side of the nut facing down towards the bearing lockwasher (Fig. 058). Fig 058 CLR DSC-0166 11. Torque the bearing nut to 150 ft-lbs. (203.37 Nm) (Fig. 059).
ATTACHMENTS 14. Place a new o-ring on the hydraulic motor (Fig. 062). Fig 062 16. Align the key of the hydraulic motor with the keyway of the auger shaft. Lower the hydraulic motor into the auger housing. Make sure the 90o hydraulic fittings face away from the traction unit (Fig. 064). CLR DSC-0194 Fig 064 CLR DSC-0199 15. Place the key in the groove of the hydraulic motor shaft (Fig. 063). 17. Install the four 3/8” hex head bolts into the hydraulic motor and fasten to the auger housing.
ATTACHMENTS 20. Torque the hydraulic fittings to 42 + 5 ft-lbs. (56.9 + 6.8 Nm) (Fig. 068). 18. Install the hydraulic hoses to the hydraulic motor Note: Replace the o-ring seals on the hydraulic fittings (Fig. 066). Fig 066 21. Install the other end of the hydraulic hoses onto the flush face couplers (Fig. 069). TX 413 Service Manual Fig 067 CLR DSC-0206 CLR DSC-0203 19. Stabilize the auger head by sliding the 1/2” x 2-3/4” bolt into cradle arm (Fig. 067).
ATTACHMENTS 22. Grease the zerks on the auger housing with a high temperature Mobil grease (Fig. 070). Trencher Chain wear cannot exceed more than 3% of its compressed length. To determine this, lay the chain on a flat surface. Push the ends in to remove all the slack. Measure its length. Next, stretch the chain by pulling the ends until all the slack is removed. Measure its length once more. If the stretch length is more than 3% longer then the compressed length, replace the chain (Fig. 071).
ATTACHMENTS Trencher Chain and Boom Removal Cap the flush face couplers to prevent hydraulic contamination (Fig. 073). 1. Remove the bolt and nut securing the spoils auger to the trencher shaft (Fig. 075). Fig 073 CLR DSC-0103 Fig 075 2. Optional: Remove the three bolts washers and nuts that are securing the safety bar for better access (Fig. 074). Slide the spoils auger off trencher shaft (Fig. 076). Fig 076 TX 413 Service Manual Fig 074 CLR DSC-0228 Rev.
ATTACHMENTS 2. Remove the two nuts and bolts from the support plates securing the boom to the trencher arm (Fig. 077). Fig 077 4. First, remove the chain from the nose roller (Fig. 079). CLR DSC-0232 3. Loosen the jam nut (counter clockwise) on the adjustment bolt and turn the bolt out. Slide boom in towards motor to provide enough slack to remove chain from sprocket (Fig. 078). 10-22 Fig 078 Fig 079 CLR DSC-0234 Second, remove the chain from the trencher sprocket (Fig. 080).
ATTACHMENTS Nose Roller Removal 5. Slide/remove the boom from the boom mount arm (Fig. 081). 1. Remove the screw, washer and pin assembly from the nose roller (Fig. 082). Fig 081 CLR DSC-0236 Fig 082 CLR DSC-0238 2. Slide the nose roller out of the boom. Remove the roller caps from each side of the roller. Remove the slotted spacers from each side of the nose roller (Fig. 083). TX 413 Service Manual Rev.
ATTACHMENTS 3. Clean grease from nose roller to expose the retaining ring. Remove with snap ring pliers (Fig. 084). Fig 084 CLR DSC-0243 4. Block the nose roller up on a press so the bearing has room to come out. Press the bearing out of the nose roller (Fig. 086 and Fig. 087). Fig 086 CLR DSC-0244 Fig 087 CLR DSC-0245 Note: The nose roller bearing is removed from the same side of the nose roller as the retaining ring. Make sure the bearing rotates freely. Replace if necessary.
ATTACHMENTS Reassemble the Nose Roller 1. Reassemble in reverse order. Place a roller spacer against each side of the bearing surface (Fig. 088). Fig 088 CLR DSC-0246 Install the roller caps next, aligning the square of the cap with the square of the bearing hub (Fig. 089). 2. Slide the nose roller back into the boom. Install the screw, washer and pin assembly. Make sure the pin assembly lines up with roller caps and bearing hub (Fig. 090). Fig 090 CLR DSC-0248 3.
ATTACHMENTS Motor Removal Trencher Shaft Removal 1. Place drain pan under hydraulic motor. Mark one fitting on the hose to one fitting on the motor. Remove hydraulic hoses and cap all motor and hose fittings to prevent contamination to hydraulic system (Fig. 092). 1. Remove the six hex head screws from the trencher sprocket (Fig. 094). Fig 092 Fig 094 CLR DSC-0252 DSC-377 2. Bend the two tangs from the bearing lockwasher out of the bearing locknut (Fig. 095). 2.
ATTACHMENTS 3. Use a large slotted screw driver to prevent the trencher shaft from spinning and remove the bearing locknut with a spanner wrench, p/n 999-9999 (Fig. 096 and Fig. 097). 4. Remove the bearing lockwasher from the trencher shaft (Fig. 098). Fig 096 Fig 098 CLR DSC-0301 CLR DSC-0299 5. Remove the tongued washer from the trencher shaft (Fig. 099). Fig 097 CLR DSC-0300 TX 413 Service Manual Rev.
ATTACHMENTS 6. Remove the roller bearing from the trencher shaft (Fig. 100). Fig 100 8. If the motor side bearing needs replacement proceed as follows. Remove boom mount from mount assembly (Fig. 102). CLR DSC-0303 7. From the sprocket side of the trencher boom mount, remove the trencher shaft (Fig. 101). 10-28 Fig 101 CLR DSC-0305 Fig 102 CLR DSC-0353 9. Block the boom mount on a press so the spacer and shaft seal will press out freely (Fig. 103). Rev.
ATTACHMENTS 10. The roller bearing is only removed after the spacer and shaft seal have been pressed out. Inspect bearings for any damage or wear. Replace if damaged. Note: If the spacer and shaft seal are driven out of the boom mount, replace them. Do not reuse (Fig. 104). Fig 104 CLR DSC-0311 11. Drive or press out bearing cups from boom mount (Fig. 105). TX 413 Service Manual Fig 105 1. Install new bearing cups with the taper end or the manufacture name stamp towards center.
ATTACHMENTS 3. The shaft seal is installed with the step facing down toward the bearing. The green coating facing up. Press or drive the shaft seal until fully seated (Fig. 108). Fig 108 5. After the shaft side is assembled, turn the boom mount over onto its side and install bearing into the motor side (Fig. 110). Fig 110 CLR DSC-0342 CLR DSC-0337 Note: Spacer stepped side faces up (Fig. 109). 6.
ATTACHMENTS 7. Line up the tab on the tongued washer with the trencher shaft keyway and install (Fig. 112). Fig 112 9. Use a large slotted screwdriver to prevent the trencher shaft from spinning and install the bearing locknut. Torque to 45 ft-lbs. (61 Nm) (Fig. 114). CLR DSC-0347 8. Line up the inner tab of the bearing lockwasher with the trencher shaft keyway and install (Fig. 113). Note: The angle of the bearing lockwasher tabs should face up.
ATTACHMENTS 11. Rotate the shaft to ensure the bearings are properly seated. 12. Bolt the mount assembly to the boom and torque the six screws to 210 + 20 ft-lbs. (285 + 28 Nm) (Fig. 116). Note: Install sprocket before hydraulic motor. 13. The sprocket is installed with the recessed side facing the trencher arm. The arrow side faces out toward the spoils auger (Fig. 117). Note: The three inside screws are difficult to torque with a standard profile socket and torque wrench combination.
ATTACHMENTS 15. Install new o-ring onto the hydraulic motor prior to mating it with the trencher shaft (Fig. 119). Fig 119 17. Level the trencher arm before servicing the bearing reservoir. Remove the fill plug. Fill with 16 oz. of SAE 90 - 140 AP 1 Service GL-4 or GL5 (Fig. 121). CLR DSC-0362 16. Install the hydraulic motor onto the boom mount with the ports facing up. Torque the four screws to 75 + 8 ft-lbs. (102 + 11 Nm) (Fig. 120). Fig 121 CLR DSC-0364 18.
ATTACHMENTS 20. Loosely install bolts and nuts but DO NOT torque yet. Note: Do not torque until the chain is on the boom and tension has been adjusted (Fig. 123). 23. Turn the adjuster bolt until 1-1/2” - 2-1/2” (3.8 6.35cm) droop between the bottom of the boom and the top of the bottom chain span (Fig. 125). Fig 123 Fig 125 CLR DSC-0371 CLR DSC-0368 21. Use a traction unit to lift the boom to aid in the install of the chain. 24.
ATTACHMENTS 25. Hold the other side of the screw with a wrench and torque the support plate bolts to 150 + 15 ft-lbs. (203 + 20 Nm) (Fig. 127). 27. If applicable, install safety bar and torque the three screws and nuts to 210 + 20 ft-lbs. (284 + 27 Nm) (Fig. 129). Fig 127 CLR DSC-0373 26. Slide the spoils auger onto the trencher shaft. Install screw and nut into one of the two holes according to chain width. Torque to 105 + 11 ft-lbs. (142 + 15 Nm) (Fig. 128). CLR DSC-0376 28.
ATTACHMENTS THIS PAGE INTENTIONALLY LEFT BLANK. 10-36 Rev.
HYDRAULIC TROUBLESHOOTING TX 413 Service Manual Rev.
HYDRAULIC TROUBLESHOOTING Fluids Excessive Fluid Temperature Hydraulic Fluids Continuous Operation at Relief Pressure The reservoir acts as an expansion chamber and separates trapped air within the fluid. Incorrect Fluid • Drain, flush and replace with proper fluid When checking the reservoir level, examine the condition of the fluid. The presence of dirt and or metallic particles indicate a fluid and filter change along with further system troubleshooting is needed.
HYDRAULIC TROUBLESHOOTING Foaming Fluid Operational Troubleshooting Low Fluid Level • Fill reservoir to the full mark • Check system for external leaks Loss of Hydraulic Function Water in the Fluid • Drain, flush and replace fluid Incorrect Fluid • Drain, flush and replace with proper fluid Air Leak Between Reservoir and Pump • Tighten loose connection • Replace damaged hose Restricted Flow from Kinked/Dented Lines • Replace affected lines No Fluid in the System • Fill reservoir to the full mar
HYDRAULIC TROUBLESHOOTING Operational Troubleshooting cont. Slow Operation Loss of Hydraulic Function cont.
HYDRAULIC TROUBLESHOOTING Pumps Pump Troubleshooting Hydraulic pumps transfer fluids by suction, pressure, or both. Pumps convert mechanical energy into hydraulic pressure and flow. Inspect the plumbing for bent, kinked/flattened lines, leaks and dirt build up. Inspect the pump housing for discolored surfaces. Ensure the linkage is assembled correctly and it is not bent or binding. Look for evidence of recently installed parts and inquire with the owner/operator.
HYDRAULIC TROUBLESHOOTING Pumps cont.
HYDRAULIC TROUBLESHOOTING Valves Spool Valve Troubleshooting Valves are used to provide control of pressure, direction and volume in a hydraulic system. Spool valves are a type of directional control valve that allows oil flow to be diverted to a remote circuit when the spool is not centered. Bypass Valve Bypass valves are a type of flow control valve used to manually open a hydraulic circuit allowing oil to bypass from one side of a circuit to the other.
HYDRAULIC TROUBLESHOOTING Cylinders/Loader Arms Loader Arm Drops in Neutral Hydraulic Cylinders Broken or Leaky Hydraulic Lines between Control Valve and Cylinder • Check for leaks • Tighten or replace affected hydraulic line fittings Hydraulic cylinders convert hydraulic pressure and flow into linear mechanical energy. Cylinders consist of a sealed chamber, piston and piston rod.
Dingo® TX413 Compact Utility Loader Service Manual Form no.
