TANK - S
HYDRAULIC DRIVE & STEERING SYSTEM
Model Year 2009
TANK - S
HYDRAULIC DRIVE & STEERING SYSTEM
TABLE OF CONTENTS:
PAGE 2 ) ……………………………….. Table of Contents.
PAGE 3 ) ……………………………….. System Overview.
Major Components.
Part Numbers.
Hydraulic Fluid Specifications.
Capacities.
Hydraulic Oil / Fluid: Factory Spec.
Hydraulic Oil / Fluid: Alternative.
Filter Element:
PAGE 4 ) ………………………………… Maintenance Schedule.
Daily.
First 50 Hrs.
Every 100 Hrs.
Every 500 Hrs.
PAGE 5 ) …………………………………. Troubleshooting Checklist.
Unit Does not Track or Drive Straight.
Drive System Noisy.
Unit Has Low or No Power.
Hydraulic System Running Hot.
Leaks in System.
Steering Unresponsive or Jerky.
PAGE 6 ) …………………………………. Safety Precautions & Warnings.
PAGE 7 ) ……………………………........ Hydraulic Steering and Deck Lift Hose Routing And Component Chart.
PAGE 8 ) …………………………………. Hydraulic Steering and Deck Lift Hose Routing Schematic.
PAGE 9 ) …………………………………. Maintenance and Service Procedures.
Replacing the Filter.
PAGE 10 ) …………………………………Maintenance and Service Procedures.
Draining the Reservoir.
Cleaning the Reservoir.
Purging Air From System.
PAGE 11 ) …………………………………Service Hints and Tips.
O-Ring Seals.
Tightening Fittings and Hoses.
Diagnostic Flow Check.
Jms/CTP Page 2 of 11 1/10/2012
SYSTEM OVERVIEW:
The steering system incorporated on the TANK-S Unit is a system that coordinates the steer angle of the front
wheels and the speed of the rear wheels when negotiating a turn. The front steering assembly is connected to
the drive wheel hydraulic pumps by a coordinated linkage system. As the front wheels are turned in a
direction, the speeds of the rear wheels are synchronized to match the exact speed required for the turn
created by the steer angle of the front wheels.
The hydraulic steering system consists of a pump, a valve located in the steering column and a cylinder
connected to the front linkage. Turning the steering wheel, rotates the control valve sending a calibrated
amount and pressure of fluid to the steering cylinder. The cylinder positions the front wheels for the desired
turn radius.
The drive system consists of separate RH and LH pumps and RH and LH drive motors. Mechanical linkage
from the front steering system and a manually operated foot pedal connected to the individual pumps control
the speed and rotational direction of the motors.
The system is supplied from a common reservoir and filter.
MAJOR COMPONENTS:
Component CTP / Cub Cadet Part #.
Steering Cylinder – Custom Cylinder ………………………………………………………… 02003368
Steering Pump – HALDEX #1850268, 3.5 Cu. Cm/Rev …………………………………… 02003193
Steering Valve – SUER DANFOSS, M63PB ………………………………………………... 02005325
Drive Pump RH – HYDRO-GEAR, PJ-5HCC-GA1B-X …………………………………….. 02003381
Drive Pump LH – HYDRO-GEAR, PJ-5KCC-GA1B-X …………………………………….. 02003380
Filter Assembly – SCHROEDER, MTAG2277S8……………………………………………. 02002257
Filter Element - SCHROEDER G2277……………………………………………………….. 02002258
Deck Lift Cylinder – Custom Cylinder ………………………………………………………… 02003930
Deck Lift Valve – PARKER, VV13D39 ……………………………………………………….. 02004696
Cooling Fan – SPAL, VA31-A101-46A 12V …………………………………………………. 02004481
Oil Cooler/Radiator. …………………………………………………………………………….. 718-3132
HYDRAULIC FLUID SPECIFICATIONS:
Capacities:
Reservoir – Approx. 1 US Gallon.
System - Approx. 1.6 US Gallon. ( Including Reservoir)
Oil Temperature Operation Range:
Maximum Intermittent. (Hottest Point). 230 degrees F.
Normal Operating Range. -10 to 200 degrees F.
Hydraulic Oil / Fluid: Factory Spec. (Recommended).
Shell, Rimula Premium 15W40 Part # 02002058 Quarts.
Synative ES 2421, ( Ornite ) Additive. - 1.5 oz. per system. Part # 02000786 – 1.5 oz.
Hydraulic Oil / Fluid: Alternative.
CUB CADET Drive System Plus. Part # 737-3121, Gallons.
* A Name Brand Quality Oil Meeting the Following Specification.
20W50….API Service, SL……………………….Fluid Base, Mineral.
5W40…... “ , SL, CI-4 Plus………….. “ , Synthetic.
15W40…. “ , SJ, CH-4………………. “ , Synthetic Blend.
15W40…. “ , SL, CI-4 Plus………….. “ , Mineral.
*It is Recommended that Synative 2421 ( Ornite ) Part # 02000786
be added with every oil change, especially when an alternative oil / fluid is used.
Filter Element:
Replaceable, Schroeder G2277, 25 Micron Cellulose Element. Part# 02002258
Jms/CTP Page 3 of 11 1/10/2012
MAINTENANCE SCHEDULE:
Daily: (Highly Recommended)
Check the Hydraulic Oil Level in the reservoir.
Low fluid level will enable the pumps to ingest air into the system or cause the system to run
at temperatures above recommended levels. Both conditions will damage pumps and motors.
High fluid level can cause the oil to leak by the filler cap or breather when the fluid expands
during operation. Normally, this does not result in component damage.
Check the Hydraulic Hoses and Fittings for leaks, abrasion, kinks, twists or flattened hoses.
A leak in the system can cause the fluid level to drop below the recommended level during the
course of a day.
Leaks must be addressed immediately to avoid damage to components.
Kinks, twists or flatten hoses can restrict fluid flow. Restricted fluid flow can cause cavitation
within the pumps causing permanent damage.
Clean debris from the cooling fan, radiator screen and fins, and pump housings.
Each pump has a cooling fan mounted directly on the pump shaft.
Debris covering the fan guard/screen restricts air flow essential for proper cooling.
The radiator located at the rear bumper cools the return fluid before it returns to the reservoir.
Operating the unit without proper cooling can cause premature hydraulic fluid breakdown and
damaged seals, gaskets etc.
First 50 Hours: (Mandatory)
Change the Hydraulic Oil and Filter. (See Specifications)
Most initial wear or break-in of internal metal components takes place during the first 50 hrs.
Particles are suspended in the reservoir fluid and are captured in the filter before recalculating
through the system.
The amount of particles captured in the filter can restrict fluid flow to the pumps causing
cavitation resulting in poor performance or component damage.
Every 100 Hours: (Highly Recommended)
Change the hydraulic oil filter if unit is operated under severe conditions.
On the S-Series TANK , changing the filter is relatively easy and inexpensive.
Changing the filter frequently especially under severe operating conditions will insure that the
fluid going through system is clean and unrestricted.
Check the condition of the Hydraulic Oil / Fluid for Contamination and Break Down.
Light or milky color indicates water or air contamination.
Dark color or opaque indicates breakdown from heat or excessive component wear.
*Change the hydraulic oil and filter if any of the above conditions are evident.
* If the hydraulic oil appears contaminated or dark colored, monitor and service more
frequently than the recommended schedule.
Every 500 Hours: (Mandatory)
Change the Hydraulic Oil and Filter. (See Specifications).
Under normal operating conditions, at about 500 hrs., the Hydraulic Oil may begin to
breakdown.
The lubricity and the effectiveness of the oil additives may begin to loose their properties due
to normal wear and heat.
Contaminants as wear particles, dirt and moisture are usually evident after the duration of
the recommended time period.
*It is imperative that the Fluid and Filter be changed at this time.
*Units used under extreme or severe operating conditions the system should be serviced
more frequently than the recommended schedule.
NOTE: Failure to follow the recommended maintenance schedule can effect performance and shorten the
service life of components within the system.
Failure to follow the mandatory service items can jeopardize warranty coverage.
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TROUBLE SHOOTING CHECKLIST
Possible Cause Corrective Action
UNIT DOES NOT DRIVE/TRACK STRAIGHT
Tires improperly inflated………………………………………. Refer to units’ manufacturer suggested pressure.
Control linkage bent, loose or out of adjustment…………… Repair, adjust or replace drive linkage.
Bypass loose…………………………………………………… Tighten pump bypass valve.
Inlet Leak……………………………………………………….. Check all external lines and connections to pump inlet.
DRIVE SYSTEM IS NOISY
Excessive input speed………………………………………… Adjust input speed above 1800 rpm and below 3600 rpm.
Oil level low or contaminated oil……………………………… Fill reservoir to proper level or change oil.
Excessive loading……………………………………………… Reduce vehicle load.
Air trapped in hydraulic system………………………………. Purge hydraulic system per Purging Procedures.
Bypass loose…………………………………………………... Tighten pump bypass valve.
Inlet leak, line or filter partially blocked or damaged………. Check all external lines and connections and the reservoir
filter to the pump inlet.
UNIT HAS NO / LOW POWER
Engine speed low……………………………………………… Adjust to correct rpm setting.
Control linkage bent, loose or out of adjustment…………... Repair, replace or adjust vehicle linkage.
Drive belt slipping or pulley damaged………………………. .Repair or replace drive belt or pulley.
Oil level low or contaminated oil……………………………... Fill reservoir to proper level or change oil.
Excessive loading…………………………………………….. .Reduce vehicle load.
Bypass loose…………………………………………………… Tighten pump bypass valve.
Air trapped in hydraulic system………………………………. Purge hydraulic system.
Inlet leak………………………………………………………… Check all external lines and connections to pump inlet.
Inlet filter clogged……………………………………………… Replace inlet filter.
Suspected internal damage………………………………….. Check pump by performing Flow Test.
HYDRAULIC SYSTEM OPERATING HOT
Debris buildup…………………………………………………. Remove debris from pump, fan and radiator.
Cooling fan not working or heat exchanger damaged…….. Repair or replace cooling fan or heat exchanger.
Oil level low or contaminated oil……………………………... Fill reservoir to proper level or change oil.
(Check for Leaks)
Excessive loading……………………………………………… Reduce vehicle load.
Air trapped in hydraulic system………………………………. Purge hydraulic system.
Inlet leak……………………………………………………….. Check all external lines and connections to pump inlet.
PUMP / SYSTEM LEAKS OIL
Damaged pump seals or gaskets……………………………… Replace seals.
Loose Fittings…………………………………………………… Tighten as required. Check “O” rings at fittings.
Cracked or broken fittings or component housings………… Check fittings and components. Cracked pump housings
indicate pump internal damage.
Damaged “O” rings, fittings & hoses…………………………. Check all external lines and connections; replace seals
and “O” rings as required.
STEERING UNRESPONSIVE OR JERKY
Air in System …………………………………………………… Purge System.
Leak at fittings or hoses ………………………………………. Check for leaks.
Hoses not installed correctly at the steering cylinder………. Check installation and routing diagram.
Hoses kinked, pinched causing flow restriction. ……………. Check all hoses and lines.
Faulty or damaged pump ……………………………………… Check pump by performing Flow Test.
Faulty or damaged cylinder …………………………………… Check cylinder operation.
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SAFETY PRECAUTIONS AND WARNINGS:
Always Wear Proper Protective Clothing and Eye Protection When Performing Service
or Maintenance Procedures.
Spilled or Leaking Hydraulic Oil / Fluid Causes Slippery Surfaces as Floors and Tools.
Keep Areas and Surfaces Clean.
Use Extreme Caution When Working With High Temperature and High Pressure Systems.
PERFORMING SERVICE or MAINTENANCE w/ ENGINE NOT RUNNING:
1. Apply Parking Brake.
2. Remove Key From Ignition.
3. Disconnect Spark Plug Wires.
4. Disconnect Battery.
5. Allow Engine and Hydraulic System to Cool Sufficiently.
PERFORMING SERVICE or MAINTENANCE w/ ENGINE RUNNING:
1. Apply Parking Brake.
2. While Engine is Running, Perform Observation Checks Only.
3. Keep Body and Hands Away From Fittings, Hoses and Components While Searching for Leaks.
Hydraulic Fluid Under High Pressure Can Pierce the Skin Causing Injury and Serious Infection.
Use a Piece of Cardboard or Paper to Search and Identify Leaks. Not Hands.
4. Do not attempt any Adjustments with Engine Running.
5. Do Not Attempt to Loosen or Tighten Fittings or Hoses w/ Engine Running.
6. High Temperatures Created by the Hydraulic System and Engine Can Cause Serious Burns.
PERFORMING SERVICE OR MAINTENANCE W/ UNIT RAISED OFF THE GROUND:
Certain procedures require the unit to be jacked up or raised off the ground.
Always perform procedures on flat level ground.
Always secure unit while raised with stationary blocks or jack stands.
WARNINGS PERTAINING TO HYDRAULIC SYSTEMS AND DEVICES:
Hydraulic oil / fluid escaping under pressure may have sufficient force to penetrate skin causing
serious injury. If foreign fluid is injected into the skin, it must be surgically removed within a few hours
by a doctor familiar with this form of injury, or gangrene may result.
Never attempt service or maintenance procedures while the hydraulic system is pressurized.
To safely relieve all pressure in the system.
1. Turn Ignition Off and Remove the Key.
2. Apply Parking Brake.
3. Disconnect Spark Plug Wires.
4. Disconnect Battery.
5. Open By-pass Valves.
6. Operate Hydraulic Controls to Release Pressure within Pumps, Cylinders, Motors,
Valves and Lines / Hoses.
After completion of the above operations, internal pressures should be relieved, disconnecting lines
and components can begin.
As a precaution, place a cloth over fittings and gently loosen the connection.
This will offer some protection if residual pressure is present.
Make sure all fittings and components are tight and hoses / lines are in good condition before applying
pressure to the system.
For complete Safety Precautions and Warnings related to the S-Series TANK,
consult the Operators / Service Manual furnished with every unit.
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Hydraulic Steering & Deck Lift Hose
Routing and Component Diagram.
Hydraulic Steering & Deck Lift Routing Schematic.
Jms/CTP Page 8 of 11 1/10/2012
Cap Mounting
Screws, (3).
Return Fitting
Fill Cap
Feed Line to
Steering Pump
Filtered Feed Line
to Drive Pumps
Filter Cartridge.
O-Ring
Siphon Bowl Inlet
MAINTANCE AND SERVICE PROCEDURES:
REPLACING THE FILTER:
Park the unit on a flat level surface.
Apply the brake.
Remove the ignition key.
Disconnect the battery.
Disconnect the spark plug wires.
If the unit has been running, allow engine and hydro system to cool sufficiently.
Clean the area around the fill cap and filter assembly.
Carefully, remove the three screws (3/8” wrench) securing the cap on the filter housing. See Fig.1.
Fig. 1 Remove cap. Fig. 2.
The filter and cap are spring loaded. Use caution when removing the screws and cap. See fig. 2.
Remove filer cartridge from housing. See Fig. 3.
Pay careful attention to the O-Ring seal around the top lip of the bowl. Do Not Damage.
Using a hook fashioned out of stiff wire and inserted through the siphon bowl inlet tube in the bottom
of the bowl can make lifting the bowl out of the housing easier.
Be sure that the O-ring seal is undamaged & properly seated in the cap groove and coat with oil.
Tighten the screws each evenly to avoid cocking the cap when tightened into the housing.
O-ring seal between the siphon cup and housing.
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Fig. 3 Fig. 4.
Remove the plastic siphon bowl from the housing. See Fig. 4
Wipe the bowl clean, concentrating on the inside bottom of the bowl were debris can accumulate.
Re-insert the bowl into the housing. Be sure the O-ring is in place and coated with oil.
Inset the new filter into the bowl. Flat end w/o center hole is toward the top or cap. Fig. 2.
Reinstall the cap.
Check and add, if necessary, oil to the reservoir.
Run unit to operating temperature and recheck oil level. Add if necessary
If air is evident after running, Check the O-ring seal between the cap and the housing and the
DRAINING THE RESERVOIR HYDRAULIC OIL:
Park the unit on a flat level surface.
Apply the brake.
Remove the ignition key.
Disconnect the battery.
Disconnect the spark plug wires.
If the unit has been running, allow engine and hydro system to cool sufficiently.
Clean the area around the fill cap, filter assembly and bottom surface of the reservoir tank.
Lower the deck to the lowest position.
Place a 1 gal. shallow pan under the reservoir.
Carefully remove the drain plug (5/8” wrench) allowing the oil to drain into the pan.
After oil is thoroughly drained, wipe the reservoir drain opening and drain plug clean.
Replace drain plug.
Fill reservoir to specified level with Shell - Rimula Premium 15W40 Oil plus Ornite Additive.
SEE: Hydraulic Oil / Fluid Specifications, Page 3.
Run unit to operating temperature and recheck oil level. Add if necessary.
CLEANING THE RESERVOIR:
*It is recommended that the reservoir be cleaned at the 500 hr. servicing.
After the oil is drained from the reservoir, install the drain plug.
Remove the filter and siphon bowl from the filter assembly.
Pour an appropriate solvent into the reservoir to about 1” – 2” from the bottom.
Solvents as those formulated for Parts Cleaners, Kerosene or Diesel Fuel can be used.
DO NOT USE Gasoline or other highly flammable liquids.
Always use solvents in a well ventilated area and avoid inhaling fumes or vapors.
Access through the filter housing with the cup removed.
Use a long handle brush to agitate solvent and loosen the particles in the bottom of the tank.
Drain the solvent and repeat the procedure until drained solvent is clean.
After the last flushing, use a clean lint free cloth to swab out any remaining solvent in the tank.
*Complete system cleaning and flushing is required when performing major repairs due to
component failures.
When a component fails, pieces of internal parts can become lodged in hoses, lines and fittings.
These pieces can restrict fluid flow and damage new components after installation.
Drain system as previously described.
Disconnect all hoses and lines and thoroughly clean, flush inside and inspect before reuse.
Remove the complete filter assembly from the reservoir.
Unbolt and remove the reservoir tank from the unit.
Thoroughly clean and flush the inside of the tank.
PURGING AIR FROM SYSTEM:
Controls unresponsive, hard to operate or jerky.
Air in reservoir indicated by frothy oil, light colored oil ( also can be water in oil), air bubbles observed
in reservoir while running and oil is circulating.
Always check hoses and fittings that they are properly tightened and without abrasions.
Purging the Steering / Drive System:
Jms/CTP Page 10 of 11 1/10/2012
Inspect all components before reinstalling.
Park unit on flat level surface.
Check oil level. Add if necessary.
Raise the rear (drive wheels) off the ground and secure with blocks or jack stands.
Open the drive pump by-pass valves (7/16” wrench). See operators manual.
Operate the FWD and REV control pedals at least 6 times in each direction.
Turn the steering wheel slowly from right to left.
When the full left or right stop is reached, keep turning the steering wheel until resistance is felt.
Repeat the turn right and left at least 6 times.
Close the drive pump by-pass valves, check oil level, repeat procedure with by-pass valves closed.
Repeat full procedure until proper performance is achieved.
The hydraulic oil may still have some air in it after desired performance is achieved.
Allow the fluid to settle, 4-8 hrs, and recheck.
If the fluid still indicates air in the system after purging, allowing the oil to settle and running.
Check all fittings, hoses and components for possible leaks.
BAD GOOD
BAD GOOD
GOOD BAD
SERVICE TIPS & HINTS:
O-Ring Seals:
When loosening or disassembling hoses and fittings the O-Rings can be damaged or misplaced.
It is recommended that O-Ring Seals used in hose couplers and fittings be replaced when attempting
to reuse components. If this isn’t feasible, always thoroughly inspect the O-Rings for cuts, distortion
and brittleness.
Over tightening can cause misalignment, deformation or cut the seals.
Heat generated by pumps and motors can cause seals to become hard and brittle and will not seal
properly if reused.
Tightening Fittings and Hoses:
Always, when applicable, use 2 wrenches when loosening or tightening hoses and fittings.
Avoid twisting hoses when tightening fittings. A twisted hose tends to return the it’s neutral state and
loosen at the fitting when under pressure and vibration. The results are leaks and possible 0-ring seal
damage from pressure.
Diagnostic Flow Check:
Observing the fluid flow from the return line into the reservoir tank can give an indication of certain
conditions related to the hydraulic system operation and performance.
A normal operating system will produce a strong steady flow.
A weak flow may be an indication of potential pump failure or flow restriction in the system.
Air bubbles are an indication of air being ingested into the pump intake circuit or pump cavitation.
Jms/CTP Page 11 of 11 1/10/2012
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