Comprehensive Power/Speed Adjustments - Polaris Brutus Forum
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post #1 of 14 (permalink) Old 03-26-2017, 02:29 PM Thread Starter
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Comprehensive Power/Speed Adjustments

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post #2 of 14 (permalink) Old 03-26-2017, 02:34 PM Thread Starter
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First things first, make sure your idle lever has at least spec low idle and high idle, 1200-1300rpm and 3700-3800rpm. My engine throttle without cable was set at the factory 1250 and 3750rpm. The idle lever cable failed to deliver the high idle of the engine. This problem requires trying different throttle holes and tweaking the cable mount so the idle lever has the full range from high to low.

Next step is to make the pump squash plate adjustment. This should be made at high idle on jack stands with the squash plate just moving the wheels forward then back slowly until they stop. This adjustment is described in detail elsewhere on the site.

Now make sure the treadle pedal cables are adjusted for the correct free play and the wheels do not move in high idle. While still on the jack stands in high gear the treadle pedal should achieve about 30mph fully depressed forward and about 8mph fully depressed reverse, if not make those adjustments.

Now off the jack stands the HP Commander are made as per the Bobcat Dealer.

FORWARD TRAVEL RPM CHECK (PERFORM LOADED FOR CAB VEHICLES, UNLOADED FOR NON-CAB):
This check verifies the horsepower management system is functional and adjusted correctly for optimal performance. The command torsion spring bolt can be adjusted in quarter increments beyond the baseline setting below to match personal preference or based on accessory loads and vehicle usage.

1. With transmission in HIGH range on level asphalt depress the travel control pedal to the full forward position with a quick fluid motion.
2. The engine RPM at 20 mph (32.2 km/h) should be in the range of 3400-3600 RPM for loaded testing and 3550-3650 RPM for unloaded testing. If engine RPM is not within specifications proceed to steps 3-6. If the horsepower management functionality is within specification, proceed to the FORWARD TRAVEL SPEED CHECK
3. To decrease the engine RPM (increased engine pull down), loosen the command torsion spring bolt nut (Fig.1 Item 6) and tighten command torsion spring bolt (Fig.1 Item 5) シ turn.
4. To increase the engine RPM (decreased engine pull down), loosen the command torsion spring bolt nut (Fig.1 Item 6) loosen command torsion spring bolt (Fig.1 Item 5) シ turn. Note: This setting can be adjusted to match user preference, if desired. Tightening the spring will result in increased engine pull down/lug and may require more modulation of the travel control pedal when under load. Loosening the spring decrease engine pull down/lug under load.
5. Repeat steps 3 - 5 until the RPM is within specification. If Forward Travel RPM is within specifications proceed to FORWARD TRAVEL SPEED CHECK.
FORWARD TRAVEL SPEED CHECK (PERFORM LOADED FOR CAB VEHICLES, UNLOADED FOR NON-CAB):

This check verifies the horsepower management system is functional and adjusted correctly for optimal performance with a full accessory load. The command torsion spring bolt can be adjusted in half turn increments beyond the baseline setting below to match personal preference or based on accessory loads and vehicle usage. On straight, level asphalt or concrete, mark off a distance of 250 feet (76.2 meters) for non-CAB/HVAC models and 300 feet (91.44 meters) for CAB/HVAC models.

1. With transmission in HIGH range depress the travel control pedal to the full forward position with a quick fluid motion. Vehicles equipped with CAB/HVAC should accelerate from 0-20 mph (0-32 kph) in a distance of 300 feet (91.44 meters) and vehicles without CAB/HVAC in 250 feet (76.2 meters) or less. Perform test in both directions across the testing field and average the speeds. If vehicle does not obtain the desired speed in the specified distance proceed to Step 2. If vehicle obtains the desired speed in the specified distance the performance checks procedure is COMPLETE. Reconnect hydraulic temperature sensor and clear DTC with Digital Wrench.
2. Tighten command lever torsion spring bolt シ turn to increase speed. NOTE: If the vehicle does not meet performance specifications after three complete tests contact Bobcat or Polaris Service Troubleshooting for further assistance.

Sorry this is so long, but this is a very difficult process and is why so many problems occur.
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post #3 of 14 (permalink) Old 04-03-2017, 11:01 AM Thread Starter
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The infamous Command Lever as modified by Interceptor. If you are willing to modulate the treadle pedal yourself, basically letting the treadle pedal return some towards low idle when the engine is about to stall, this is the way to go. You can forget all about the HP Management adjustments above by making Interceptor's Command Lever Modification.

It works by locking the pump's Pintle Lever to the Command Lever. Yes if you mash the pedal to the floor on take off you will stall the engine, I have not found this to trouble me in the least, the modification works wonderfully.

Totally Recommend.
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post #4 of 14 (permalink) Old 04-03-2017, 11:27 AM Thread Starter
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The Command Lever Mod by Interceptor is the screw in the lower left hand corner of the picture.
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post #5 of 14 (permalink) Old 04-14-2017, 09:30 AM Thread Starter
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As you can see we are moving beyond what the Dealer can do and into what can be done to deliver more power for inclines and more top end.

If your Brutus is under warranty, the command lever and following modifications will void your warranty.

That said, the quest to realize the true promise of the Brutus concept goes on. We will find the maximum power and speed that can be attained with the components provided.
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post #6 of 14 (permalink) Old 04-14-2017, 09:37 AM Thread Starter
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The next step is fuel. Increasing diesel engine fuel to a point increases power across the RPM range. Increasing RPMs will add horsepower. We will do both. Now I will go make adjustments and report the optimum modifications here.
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post #7 of 14 (permalink) Old 04-19-2017, 08:29 PM Thread Starter
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How to get that confounded tube off without losing your mind. Use a puller. A trip to the hardware store for 3/8ths - 16 bolts and T-Nuts, please see the photo.
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post #8 of 14 (permalink) Old 04-19-2017, 08:35 PM Thread Starter
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Now modify the T-Nut flange as in this photo. Notice the arcs ground into them. The Arc size is relative to an 18mm diameter.
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post #9 of 14 (permalink) Old 04-19-2017, 08:54 PM Thread Starter
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As you can see in this picture how those arcs work. I used a 10mm socket on the acorn nut on the other end and the tube popped right off!
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post #10 of 14 (permalink) Old 04-19-2017, 09:07 PM Thread Starter
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One full turn counter clockwise and the power is there! Climbed a hill in High about 10-12 mph that would always stall before. Low would only do 6 mph before now it's 11-13 mph. These are on about a 25 incline. Acceleration is much better too. A noticeable quieting of the engine top end and mellowing of the exhaust note has also been realized.
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