Fiat Kobelco SL30B Skid Steer Loader Service Manual - PDF DOWNLOAD

SL30B SKID STEER LOADER SERVICE MANUAL ENGLISH Serial No. 604.13.057.01

Edition: 07/2002 English- Printed in Italy Printed by Studio ti

AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs.

Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation.

Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section.

A careful operator is the best insurance against an accident.

The complete observance of one simple rule would prevent many thousand serious injuries each year.

That rule is: Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support - Documentation Centre Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY

All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.

06202 60413057

On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing.

If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

SL30B Service Manual Table of Contents Description General Section Index - General Safery Precautions Standard Torque Specifications Fluids and Lubricants Loctite Product Chart

Section No. Tab 1 I-VIII 1001 1002

Engines Section Index - Engines Engine and Radiator Removal and Installation Engine Accessories

Tab 2

Fuel System Section Index - Fuel System Fuel System and Filters

Tab 3

Electrical Section Index - Electrical Removal and Installation of Electrical Components Electrical Specifications and Troubleshooting Battery

Tab 4

Power Train Section Index - Power Train Removal and Installation of Power Train Components Hydrostatic System Troubleshooting

Tab 6

Pressure Reducing Valve and Sequence Valve Piston Pumps Drive Motors Sprocket, Chains, and Axle Housings Brake Valve Wheels and Tires

6003 6004 6005 6007 6008 6011

Hydraulics Section Index - Hydraulics Removal and Installation of Hydraulic Components Hydraulic System Troubleshooting

Tab 8

2000 2001

3002

4000 4002 4005

6000 6002

8000 8002

SL30B Service Manual Table of Contents Description Cleaning the Hydraulic System and Hydrostatic System Hydraulic Pump Loader Control Valve Auxiliary Control Valve Cylinders Mounted Equipment Section Index - Mounted Equipment Pedals and Levers Loader ROPS Canopy, Seat, Seat Belts, and Operators Compartment Auxiliary Hydraulic Installation

Hydraulic and Electrical Schematic

Section No. 8003 8004 8005 8006 8007 Tab 9 9000 9002 9003 9004

I

PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”, “WARNING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.

CAUTION: The word “CAUTION” is used where a safe behavioral practice according to operating and maintenance instructions and common safety practices will protect the operator and others from accident involvement.

WARNING: The word “WARNING” denotes a potential or hidden hazard which has a potential for serious injury. It is used to warn operators and others to exercise every appropriate means to avoid a surprise involvement with machinery.

DANGER: The word “DANGER” denotes a forbidden practice in connection with a serious hazard.

Failure to follow the “CAUTION”, “WARNING”, and “DANGER” instructions may result in serious bodily injury or death.

MACHINE SAFETY Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are followed by specific instructions.

These statements are intended for machine safety.

ATTENTION: The word “ATTENTION” is used to warn the operator of potential machine damage if a certain procedure is not followed.

IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

II

SAFETY PRECAUTIONS Equipment should be operated only by those who are responsible and instructed to do so. Unsafe operating practices and improper use of the skid-steer loader and its attachments on the part of the operator can result in injuries.

Observe the following safety precautions at all times:

1.

Give complete and undivided attention to the job at hand so that complete control of the loader is maintained at all times.

2.

Be aware of ground conditions, drive slowly over rough ground and on slopes, keep alert for holes, ditches and other irregularities that may cause the loader to overturn.

3.

Avoid steep hillside operation which could cause the loader to overturn.

4.

Never transport a loaded bucket at full height.

Operate the loader with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc.

III

5.

Reduce speed when turning so there is no danger of the loader overturning.

6.

Never drive up or back up a hill or incline with a raised boom or the loader could overturn.

7.

Always look behind you before backing the loader.

8.

Maintain proper transmission oil level to prevent loss of hydrostatic braking. Check fluid levels on a regular basis as directed in this manual.

9.

Do not allow passengers to ride on the loader at any time.

IV

10. Do not allow children to operate the loader or ride on the loader at any time.

11. Do not allow anyone to operate the loader without proper instruction. Legislation in many countries require that all operators be instructed on the proper procedures and operation of the machine before use.

12. Do not operate the loader in any position other than while in the operator’s seat with the seat belt securely fastened.

13. Before starting the engine, be sure that all operating controls are in neutral and parking brake is engaged.

14. Never operate the loader engine in a closed building without adequate ventilation.

V

15. Refuel the loader outdoors with the engine shut off. Replace the fuel cap securely. Use an approved fuel container. Do not smoke when handling fuel. Avoid spilling fuel.

16. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool.

17. Dress appropriately - wear relatively tight-fitting clothing when operating the loader. Loose or torn clothing can catch in moving parts or controls.

18. Before servicing the loader or any of its attached equipment, be sure that the attachments are lowered to the ground or that the boom arms are supported by the boom lock pins.

VI

19. Do not work under overhangs, electric wires, or where there is danger of a slide.

20. Wear an approved safety hat when operating the machine and while in any work area. Wear a suitable hearing protective device such as earmuffs or earplugs if you are exposed to noise exceeding 85dBa. In the interests of safety and personnel comfort, protective clothing, boots and gloves should be worn where appropriate.

21. When driving the loader on a road or highway, use warning lights or warning devices as may be required by local or state government regulations.

Warning lights and signs are available through your dealer.

22. Keep the loader clean. Do not allow trash, debris or other articles to accumulate in the cab, floor or foot control pedal area that may hinder safe machine operation.

VII

23. Under no circumstances should the frame, screens, or protective structures be modified.

Never operate the loader with any of the shielding removed. Never operate the loader without windows and/or screens in place. Never extend any part of the body outside of the operator’s area.

24. Always properly tie down the skid-steer loader to a truck or trailer before transport.

25. Make sure all bystanders are at a safe distance away from the loader before starting the engine.

26. Do not allow anyone near the loader while the engine is running and the loader is operational.

VIII

27. When using the skid-steer loader to crane objects, do not allow any person to ride on objects being craned.

28. Do not use the skid-steer loader as a work platform for supporting materials.

29. Do not lift personnel or allow personnel to work while standing in the bucket or on other attachments. This is not a man-lift.

IMPORTANT: Legislation in many countries state it is the employer’s responsibility to fully instruct each operator in the proper and safe operation of all operative equipment. Both employer and employee should therefore thoroughly familiarise themselves with the contents of this manual.

IMPORTANT: Legislation in many countries state it is an employees' responsibility to fully understand the vehicle operation and ensure safe handling and prevent harm to themselves or others. Therefore thoroughly familiarise yourself with the contents of this manual.

IMPORTANT: ``Do not put the machine into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the directive’’ 89/392/EEC.

SECTION INDEX - GENERAL Section Title Section Number Standard Torque Specifications .................................................................................................................................. 1001 Fluids and Lubricants ............................................................................................................................................... 1002 Loctite Product Chart

21199

SPICER OFF-HIGHWAY AXLE DIVISION

7

1001 Section 1001 STANDARD TORQUE SPECIFICATIONS

1001-2

TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE ....................................................................................................... 3 Grade 5 Bolts, Nuts, and Studs .................................................................................................................................. 3 Grade 8 Bolts, Nuts, and Studs .................................................................................................................................. 3 TORQUE SPECIFICATIONS - METRIC HARDWARE ........................................................................................................

Grade 8.8 Bolts, Nuts, and Studs ................................................................................................................................

Grade 12.9 Bolts, Nuts, and Studs ..............................................................................................................................

Grade 10.9 Bolts, Nuts, and Studs ..............................................................................................................................

4 4 4 4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ...........................................................................................

37 Degree Flare Fitting .............................................................................................................................................

Straight Threads with O-ring ......................................................................................................................................

Split Flange Mounting Bolts .......................................................................................................................................

O-Ring Face Seal End ..............................................................................................................................................

O-Ring Boss End Fitting or Lock Nut ....................................................................................................................................................

Pipe fittings .............................................................................................................................................................

5 5 5 6 6 6 7

Temp ate Date: 1997_01_13

A t+ to disp ay temp ate i ormatio 1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Size

Newton metres

1/4 inch

10 to 12

5/16 inch

21 to 24

3/8 inch

38 to 43

7/16 inch

61 to 69

1/2 inch

94 to 104

9/16 inch

132 to 149

5/8 inch

183 to 210

3/4 inch

325 to 370

7/8 inch

530 to 595

1.0 inch

790 to 890

1-1/8 inch

980 to 1100

1-1/4 inch

1385 to 1555

1-3/8 inch

1810 to 2030

1-1/2 inch

2400 to 2700

Grade 8 Bolts, Nuts, and Studs

Size

Newton metres

1/4 inch

15 to 16

5/16 inch

30 to 34

3/8 inch

54 to 60

7/16 inch

86 to 97

1/2 inch

132 to 149

9/16 inch

191 to 213

5/8 inch

260 to 293

3/4 inch

480 to 515

7/8 inch

745 to 835

1.0 inch

1120 to 1280

1-1/8 inch

1585 to 1785

1-1/4 inch

2215 to 2235

1-3/8 inch

2930 to 3295

1-1/2 inch

3895 to 4375

NOTE: Use thick nuts with Grade 8 bolts.

Temp ate Date: 1997_01_13

A t+ to disp ay temp ate i ormatio

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given.

These values apply to fasteners with both coarse and fine threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used. Use of a click type torque wrench, or better is required.

Grade 8.8 Bolts, Nuts, and Studs 8.8

Grade 10.9 Bolts, Nuts, and Studs 10.9

Newton metres

Size M4

5 to 6

M5

8 to 9

M6

14 to 15

M8

33 to 37

M10

65 to 74

Newton metres

M12

114 to 128

M14

183 to 205

M4

3 to 4

M16

285 to 320

M5

5 to 6

M20

555 to 620

M6

10 to 11

M24

955 to 1075

M8

23 to 26

M30

1900 to 2140

M10

46 to 51

M36

3315 to 3730

M12

80 to 90

M14

128 to 145

M16

200 to 220

M20

400 to 450

M24

690 to 780

M30

1375 to 1545

M36

2400 to 2700

Size

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

Temp ate Date: 1997_01_13

A t+ to disp ay temp ate i ormatio 1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting Nom. SAE Dash Size

Tube OD/Hose ID

Thread Size

Newton metres

-2

5/16 - 24

8 to 9

-3

3/8 - 24

11 to 12

-4

6.4 mm

7/16 - 20

14 to 16

-5

7.9 mm

1/2 - 20

18 to 21

-6

9.5 mm

9/16 - 18

27 to 33

-8

12.7 mm

3/4 - 16

46 to 56

-10

15.9 mm

7/8 - 14

77 to 85

-12

19.0 mm

1-1/16 - 12

107 to 119

-14

22.2 mm

1-3/16 - 12

127 to 140

-16

25.4 mm

1-5/16 - 12

131 to 156

-20

31.8 mm

1-5/8 - 12

197 to 223

-24

38.1 mm

1-7/8 - 12

312 to 338

Straight Threads with O-ring Nom. SAE Dash Size

Tube OD/Hose ID

Thread Size

Newton metres

-2

5/16 - 24

8 to 9

-3

3/8 - 24

11 to 12

-4

6.4 mm

7/16-20

20 to 25

-5

7.9 mm

1/2-20

27 to 33

-6

9.5 mm

9/16-18

43 to 54

-8

12.7 mm

3/4-16

73 to 90

-10

15.9 mm

7/8-14

100 to 124

-12

19.0 mm

1-1/16-12

138 to 173

-14

22.2 mm

1-3/16-12

173 to 216

-16

25.4 mm

1-5/16-12

203 to 253

-20

31.8 mm

1-5/8-12

308 to 357

-24

38.1 mm

1-7/8-12

492 to 542

Temp ate Date: 1997_01_13

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1001-6

Split Flange Mounting Bolts Size

Newton metres

5/16-18

20 to 27

3/8-16

27 to 34

7/16-14

47 to 61

1/2-13

74 to 88

5/8-11

190 to 203

O-Ring Boss End Fitting or Lock Nut

O-Ring Face Seal End Nom. SAE Dash Size

Tube OD

Thread Size

Newton metres

Thread Size

Newton metres

-4

6.4 mm

9/16-18

23 to 26

-6

9.5 mm

11/16-16

34 to 40

9/16-18

48 to 54

-8

12.7 mm

13/16-16

52 to 57

3/4-16

70 to 78

-10

15.9 mm

1-14

81 to 90

7/8-14

102 to 114

-12

19.0 mm

1-3/16-12

117 to 128

1-1/16-12

142 to 160

-16

25.4 mm

1-7/16-12

152 to 174

1-5/16-12

237 to 254

-20

31.8 mm

1-11/16-12

179 to 201

-24

38.1 mm

2-12

213 to 235

Temp ate Date: 1997_01_13

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Pipe fittings Nom. SAE Dash Size

Thread Size

TFFT (Turns For Finger Tight)

-2

1/8 - 27

2.0 - 3.0

-3

1/8 - 27

2.0 - 3.0

-4

1/8 - 27

2.0 - 3.0

-5

1/8 - 27

2.0 - 3.0

-6

1/4 - 18

1.5 - 3.0

-8

3/8 - 18

2.0 - 3.0

-10

1/2 - 14

2.0 - 3.0

-12

3/4 - 14

2.0 - 3.0

-14

3/4 - 14

2.0 - 3.0

-16

1 - 11 1/2

1.5 - 2.5

-20

1 1/4 - 11 1/2

1.5 - 2.5

-24

1 1/2 - 11 1/2

1.5 - 2.5

-32

2 - 11 1/2

1.5 - 2.5

NOTE: Apply sealant/lubricant to male pipe threads. The first two threads should be left uncovered to avoid system contamination. Screw pipe fitting into female pipe port to the finger tight position. Wrench tighten fitting to the appropriate turns from finger tight (TFFT) shown in table above, making sure the tube end of an elbow or tee fitting is aligned to receive incoming tube or hose fitting.

21199

SPICER OFF-HIGHWAY AXLE DIVISION

7

1002 FLUIDS AND LUBRICANTS

1002

Section

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS ...................................................................................................................................

AMBIENT AIR TEMPERATURE RANGES ..................................................................................................................

Temperature Fahrenheit ........................................................................................................................................

Temperature Celsius .............................................................................................................................................

3 4 4 4

ENGINE OIL RECOMMENDATIONS .............................................................................................................................. 4 DIESEL FUEL ............................................................................................................................................................. 5 Fuel Storage ........................................................................................................................................................... 5 NOTE: The Fiat-Hitachi reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 1002-3

CAPACITIES AND LUBRICANTS Fuel Tank Capacity ....................................................................................................................................................................... 32.2 litres Engine Crankcase Capacity - with filter change .......................................................................................................................................... 6.34 litres Type of oil ................................................................................................................ See Engine Oil Recommendations on page 4 Hydraulic Reservoir Capacity - with filter change .......................................................................................................................................... 21.8 litres Capacity - without filter change .......................................................................................................................................... 20.8 litres Capacity - total system ................................................................................................................................................. 28.4 litres Type of oil ................................................................................................................................................. SAE 10W-30 engine oil Drive Chain Compartments Capacity - each side ....................................................................................................................................................... 2.8 litres Type of oil ................................................................................................................................................ SAE 10W-30 engine oil Engine Cooling System Capacity ......................................................................................................................................................................... 6.6 litres Type of coolant ......................................................................................... Ethylene glycol type antifreeze and water that is mixed for lowest ambient temperature at least 60/40 mix Grease Fittings Type of lubricant .......................................................................................................................................... molydisulfide grease Hydrostatic Motor Shaft Spline Type of lubricant .................................................................................................................................... Molykote, Type G grease

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

1002-4

ENGINE OIL RECOMMENDATIONS Use only oil meeting API engine oil service category CE.

654L9

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil intervals given in this manual are according to tests.

AMBIENT AIR TEMPERATURE RANGES Temperature Fahrenheit

−40° −30° −20° −10°

0°

10°

20°

30°

40°

50°

60°

70°

80°

90°

100° 110° 120°

MULTI-GRADE OIL SAE 20W - 50 SAE 20W - 40 SAE 15W - 40 SAE 10W - 40 SAE 10W - 30 SAE 5W - 30 SAE 5W - 20 SINGLE GRADE OIL SAE 40 SAE 30 SAE 20W - 20 SAE 10W −40° −34° −29° −23° −18° −12°

−7°

−1°

4°

10°

Temperature Celsius

16°

21°

27°

32°

38°

43∞°

49°

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 1002-5

DIESEL FUEL Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption.

In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note.

NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel is below the cloud point (wax appearance point), wax crystals in the fuel will cause the engine to lose power or not start.

Fuel Storage If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

The diesel fuel used in this machine must meet the specifications in the chart below or Specification D975-81 of the American Society for Testing and Materials.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum .................................................................................................................................................................... 34 Flash Point, Minimum .............................................................................................................................................................. 60˚ C Cloud point (wax appearance point), maximum ..................................................................................... −20˚ C See Note above Pour point, maximum ......................................................................................................................... −26˚ C See Note above Viscosity, at 100˚ F (88˚ C) Centistokes ....................................................................................................................................................................... 2.0 to 4.3 Saybolt Seconds Universal .................................................................................................................................................. 32 to 40

7

Yellow Clear Blue Purple

Purple

Brown Blue Red Green Red Red Green Red Green Clear Clear Clear Clear Clear Clear Clear Clear Clear White/Black

Clear

Clear Clear Brt Orange Light Blue Red Purple

80 123 220 221

222

225 242 262 270 271 272 275 277 290 *404 *406 *409 *414 *415 *416 *420 *422 *430 *445

*454

*495 *496 504 509 510 515

515

454

454 454

454

495

271 271 262 620 277

222

290 222

0.1016 0.127 0.762 0.508 0.508 0.254

0.254

0.254 0.0127 0.0127 0.1778 0.1778 0.1778 0.254 0.254 0.0762 0.1524 0.1016 0.2034 0.1524 0.254 0.254 0.0508 0.0508 0.0127 0.250

0.0127

0.0762 0.0127

Gap (In mm)

175.78 kg/cm2 175.78 kg/cm2 52.77 kg/cm2 52.77 kg/cm2 70.31 kg/cm2 52.77 kg/cm2

225 kg/cm2

20.41/11.34 in kg 36.29/22.68 in kg 72.58/86.18 in kg 172.58/145.15 in kg 72.58/145.15 in kg 81.65/99.79 in kg 95.26/136.08 in kg 102.06/136.08 in kg 38.56/158.76 in kg 225 kg/cm2 225 kg/cm2 175.78 kg/cm2 175.78 kg/cm2 175.78 kg/cm2 175.78 kg/cm2 175.78 kg/cm2 196.87 kg/cm2 175.78 kg/cm2 140.61 kg/cm2

24.04/13.61 in kg

25.86/64.86 in kg 34.02/19.95 in kg

Strength (Steel/Steel)

Working Fixture/Full Cure Temperature (Steel/Steel) Time Range-Farenheit Primer Description N/A Form a Gasket (works with oil, fuel or 24 hr grease) Pliable Fast N/A Weatherstrip Adhesive N/A N/A Parts Cleaner Fluid -18 to +121 6 min/24 hrs 747 Wicking Threadlocker -18 to +149 2 min/24 hrs 747 Low Strength Threadlocker Low Strength Threadlocker -18 to +149 20 min/24 hrs 764 (Small Screws) -18 to +149 7 min/24 hrs 747 Low Strength Threadlocker -18 to +149 10 min/24 hrs 764 Medium Strength Threadlocker -18 to +149 5 min/24 hrs 747 High Strength Threadlocker -18 to +149 3 min/24 hrs 747 High Strength Threadlocker -18 to +149 10 min/24 hrs 764 High Strength Threadlocker -18 to +232 30 min/24 hrs 764 High Temperature, High Strength -18 to +149 3 min/24 hrs 747 High Strength Threadlocker -18 to +149 60 min/24 hrs 764 High Strength Threadlocker -18 to +149 6 min/24 hrs 764 Wicking Threadlocker -18 to +82 30 sec/24 hrs NA Instant Adhesive -18 to +82 15 sec/24 hrs N/A Surface Insensitive Adhesive -18 to +82 50 sec/24 hrs N/A Gel Instant Adhesive -18 to +82 30 sec/24 hr N/A Instant Adhesive -18 to +82 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals) -18 to +82 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics) -18 to +82 15 sec/24 hrs N/A Wicking Instant Adhesive -18 to +82 60 sec/24 hrs N/A Gap Filling Instant Adhesive -18 to +82 20 sec/24 hrs N/A Metal Bonding Adhesive 5 min/24 hrs N/A Fast Setting 2 Part Epoxy -18 to +82 Surface Insensitive Gen -18 to +82 15 sec/24 hrs N/A Instant Adhesive 20 sec/24 hrs N/A General Purpose Instant Adhesive -18 to +82 -18 to +82 20 sec/24 hrs N/A Metal Bonding Adhesive -18 to +149 90 min/24 hrs None Rigid Gasket Eliminator -18 to +160 6 hr/72 hrs 764 Flange Sealant -18 to +204 30 min/24 hrs 764 High Temperature, GAsket Eliminator -18 to +149 1 hr/24 hrs 764 Gasket Eliminator 515

* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity

Dark Brown

#3

Rac 8-98902

Color

Product

Similar Products

LOCTITE PRODUCT CHART

Color Red Brown

Purple

Orange Red White Orange Brown Brown Brown White White Black Green Green

Green

Green Green Green Silver Green Green Clear Amber Amber Amber Yellow Clear Clear Green Silver

Product 518 542

545

549 554 567 568 569 570 571 572 592 593 601 609

620

635 638 640 660 675 680 706 707 736 738 747 751 755 764 767

N/A

609 635 755

680 680 620

640

609

504 277 592 277 545 592 592 578.575

0.254 0.381 0.1778 0.508 0.0127 0.381 N/A N/A N/A N/A N/A N/A N/A N/A N/A

0.381

0.508 0.381 N/A 0.381 0.254 N/A 0.381 N/A 0.508 0.250 0.0127 0.0127

N/A

Similar Gap Products (In Inches) 515 0.762 569 N/A

-18 to +149 -18 to +149 -18 to +204 -18 to +149 -18 to +149 -18 to +149 -18 to +149 -18 to +149 -18 to +204 -35 to +204 -18 to +149 -18 to +149 -18 to +232 -18 to +149 -18 to +149 -18 to +204 -18 to +149 -18 to +149 -18 to +149 N/A N/A N/A N/A N/A N/A N/A N/A -65 to +1600

175.78 108.86/108.86 in kg 35.15 kg/cm2 175.78 kg/cm2 18.14/11.34 in kg 11.34/18.14 in kg 18.14/9.07 in kg 36.29/12.25 in kg 35.15 kg/cm2 28.12 kg/cm2 210.93 kg/cm2 210.93 kg/cm2 210.93 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2

281.22 288.25 210.93 210.93 210.93 281.22 N/A N/A N/A N/A N/A N/A N/A N/A N/A

-18 to +149

kg/cm2

Working Temperature Range-C° -18 to +149 -18 to +149

11.34/9.07 in kg

Strength (Steel/Steel) 35.15 kg/cm2 59.88/41.73 in kg

1 hr/24 hrs 10 min/24 hrs 1 hr/24 hrs 20 min/24 hrs 20 min/24 hrs 10 min/24 hrs N/A N/A N/A N/A N/A N/A N/A N/A N/A

30 min/24 hrs

2 hr/24 hrs 2 to 4 hrs/24 hrs 4 hrs/24 hrs 12 hrs/24 hrs 1 hr/24 hrs 6 hrs/72 hrs 2 to 4 hrs/24 hrs 24 hrs/72 hrs 4 hrs/72 hrs 30 min/24 hrs 10 min/24 hrs 10 min/24 hrs

4 hr/24 hrs

1hr/24 hrs 2 hr/24 hrs

Fixture/Full Cure (Steel/Steel) Time Primer Description 764 Gasket Eliminator 518 for Aluminum 747 Hydraulic Sealant Low Strength Pneumatic/Hydraulic 747 Sealant 747 Instant Seal Plastic Gasket 764 Refrigerant Sealant 764 Pipe Sealant for Stainless Steel 764 Plastic Gasket 764 Hydraulic Sealant 764 Steam Sealant 764 Pipe Sealant None Gasketing 736 Pipe Sealant with Teflon N/A RTV Silicone 764 Current PIN #609 764 General Purpose Retaining Compound High Temperature Retaining 747 Compound 747 High Strength Retaining Compound 747 High Strength Retaining Compound 747 High Temperature Retaining Compound 764 Quick Metal 747 General Purpose Retaining Compound 747 High Strength Retaining Compound N/A Cleaning Solvent N/A Activaltor for Structural Adhesives N/A Primer NF N/A Depend Activator N/A Primer T N/A Activator for Structural Adhesives N/A Cleaning Solvent N/A Primer N N/A Anti-Seize Lubricant

LOCTITE PRODUCT CHART

SECTION INDEX - ENGINE Section Title Section Number Engine and Radiator Removal and Installation .............................................................................................................. 2000 Engine Accessories.................................................................................................................................................. 2001

7

Section 2000

2000

ENGINE REMOVAL AND INSTALLATION

2000-2

TABLE OF CONTENTS ENGINE REMOVAL ..................................................................................................................................................... 3 Installation .............................................................................................................................................................. 4 RADIATOR ................................................................................................................................................................. 4 Removal ................................................................................................................................................................. 4 Installation .............................................................................................................................................................. 4 Radiator Installation ................................................................................................................................................................... 5 Air Cleaner Installation ............................................................................................................................................................... 6 Muffler Installation ..................................................................................................................................................................... 7 Throttle Cable Installation .......................................................................................................................................................... 8 Engine Mounting Installation ...................................................................................................................................................... 9 Tandem Pump Installation ....................................................................................................................................................... 10

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information 2000-3

ENGINE REMOVAL STEP 1

STEP 5

Start and run the engine at idle.

STEP 2

BP96C038 Disconnect the seat bar locking mechanism on each side.

BP96C016

STEP 6

Raise the loader lift arms to full height and have another person install the support strut.

STEP 3 Stop the engine and raise the seat bars.

STEP 4

BP96C039 Use the grab handles and pull the operators compartment all the way forward.

STEP 7 Open the rear door.

BP96C055 Loosen and remove the bolts, lock washers and flat washers that fasten the operators compartment to the posts at the rear of the machine.

STEP 8 Remove the radiator according to the instructions in this section.

STEP 9 Remove the radiator mounting bracket from the machine.

STEP 10 Disconnect the electrical connectors from the air restriction indicator at the air cleaner. Move the wires out of the way.

STEP 11 Disconnect the hose for the air cleaner from the engine.

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STEP 12

STEP 24

Remove the air cleaner hose and mounting bracket from the machine.

Loosen and remove the cap screw, nut, and flat washers that fasten the rear engine mount to the frame.

STEP 13

STEP 25

Remove the muffler and mounting bracket from the machine.

Move the engine away from the tandem pump and out of the machine.

STEP 14 Remove the battery cover from the machine.

Installation STEP 15 Disconnect the ground cable from the negative terminal on the battery.

Installation is the reverse sequence of removal. See the i l l u s t ra t i o n s i n t h i s s e c t i o n fo r s p e c i a l t o r q u e s a n d instructions.

STEP 16 Fasten identification tags to all electrical connectors as removed from the engine. Disconnect the electr ical connectors from the components on the engine. Move the engine wiring harness out of the way.

STEP 17 Turn the fuel shutoff valve to the OFF position.

RADIATOR Removal STEP 1

STEP 18

Make sure the engine is cool. Loosen the radiator cap on the radiator.

Disconnect the return hose from the fitting on the front fuel injector. Remove the hose from the fitting.

STEP 2

STEP 19 Loosen the clamp that fastens the supply hose to the fuel shutoff valve. Remove the hose from the fuel shutoff valve.

Open the drain valve and drain the cooling system. The cooling system capacity is approximately 11.3 litres of coolant.

STEP 20

STEP 3

Loosen the screws that fasten the throttle cable to the mounting bracket. Remove the throttle cable from the mounting bracket. Move the throttle cable out of the way.

Remove the oil cooler from the radiator. Fasten the oil cooler out of the way.

STEP 21 Connect acceptable lifting equipment to the lifting eyes on the engine.

STEP 4 Disconnect the inlet and outlet hoses from the radiator.

STEP 5 NOTE: Since the engine supports one end of the tandem pump, you must connect acceptable lifting equipment to the tandem pump to hold the tandem pump in position when the engine is removed.

Hold the radiator in place and remove the hardware that fastens the radiator to the mounting straps and the mounting plate.

STEP 22

STEP 6

Connect acceptable lifting equipment to the tandem pump to hold the tandem pump in position when the engine is removed.

Remove the radiator from the machine.

Installation

STEP 23 Loosen and remove the cap screws and lock washers that fasten the tandem pump to the flywheel housing.

Installation is the reverse sequence of removal. See the i l l u s t ra t i o n s i n t h i s s e c t i o n fo r s p e c i a l t o r q u e s a n d instructions.

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3

3

6

1

2 4 5 7 11 to 13 mm

2 4

8

7 8 BS96F209

1. Radiator - Position to maintain equal clearance between fan and shroud all the way around.

2. Rubber Mount - Lubricate with water for easier installation.

3. Radiator Mounting Bracket 4. Washer

5.

6.

7.

8.

Radiator Support Shroud Washer Cap Screw - Tighten until the rubber mount is compressed to 11 to 13 mm

Radiator Installation

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2000-6

4 2

1 3

1. Loosen Clamp Here and Remove Air Cleaner from clamp

2. Air Cleaner 3. To Engine Air Cleaner Installation

4. Clamp

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4

1

3

3

2

1. Muffler 2. Mounting Bracket

3. Clamp 4. Muffler Extension - Make sure the muffler extension is centered in the opening in the door before tightening the mounting bracket (2) or the clamps (3).

Muffler Installation

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2000-8

1

3 2

1. Throttle Cable

2. Stop

3. Mounting Bracket and Clamp, See Section 9000 for Throttle Adjustment Throttle Cable Installation

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5 4 2

4

1

2

3

3

1. Rear Engine Mount 2. Cap Screw, Tighten to 68 to 81 Nm

3. Rubber Mount (Lubricate with water for easier installation.)

4. Front Engine Mount Engine Mounting Installation

5. Bolt, Tighten to 27 to 34 Nm

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2000-10

1

4

2

3

1. Flywheel Housing 2. Pump Drive Coupling

3. Cap Screw - Tighten to 41 to 52 Nm. Use Loctite 271 on the threads.

Tandem Pump Installation

4. Cap Screw - Tighten to 68 to 81 Nm. Use Loctite 242 on the threads.

2001 Section 2001 ENGINE ACCESSORIES

2001-2

TABLE OF CONTENTS AIR CLEANER ............................................................................................................................................................

Service Interval .......................................................................................................................................................

Cleaning the Filter ....................................................................................................................................................

Checking the Switch for the Air Filter Warning Lamp (Air Restriction Indicator) ...........................................................................................................................................

Safety Filter ............................................................................................................................................................

Checking the Safety Filter .........................................................................................................................................

3 3 3

3 3 3

SPARK ARRESTER MUFFLER ..................................................................................................................................... 6

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AIR CLEANER Service Interval The element must be cleaned or replaced when the warning lamp for the air cleaner is illuminated while the engine is running.

The dust cup must be cleaned after every 10 hours of operation or daily, whichever occurs first. If the machine is being operated in bad conditions, clean the dust cup several times during the period of operation.

Cleaning the Filter It is recommended that the filter be cleaned by washing.

Washing will remove more dirt than other methods of cleaning.

STEP 3 Connect the leads of an ohmmeter to the terminals on the air restriction indicator.

STEP 4 Actuate the manometer.

STEP 5 Turn the vacuum control until the ohmmeter indicates a complete circuit.

STEP 6 Read the manometer.

STEP 7 The indication must be 5.5 to 7.0 kPa.

Wash the filter in a detergent. Mix according to instructions on the container. Do not use water pressure over 206 kPa at the nozzle. Let the filter become completely dry before you install the filter. Do not use compressed air to dry the filter. If you use a drier, do not exceed 71° C and make sure that the air is circulating in the drier.

You can use compressed air to clean the filter, but this method is not the best method. Compressed air will not r e m ove t h e c a r b o n a n d s o o t . W h e n yo u u s e compressed air, do not use more than 206 kPa at the nozzle. Hold the nozzle 25 mm or more away from the filter. Apply compressed air to the inside of the filter only.

After the filter is clean and dry, check the filter. Put a lamp inside the filter and check for holes or splits in the pleats. Check for damage to the metal parts and rubber gasket. Replace the filter if the filter is damaged.

NOTE: Check a new filter the same way. Do not use a new filter that is damaged.

Checking the Switch for the Air Filter Warning Lamp (Air Restriction Indicator) STEP 1

STEP 8 If the air restriction indicator does not close at the specified vacuum, install a new air restriction indicator.

Safety Filter A safety filter is welded to the outlet of the air cleaner body. The restriction indicator is connected to the fitting.

The safety filter prevents air from entering the engine if the restriction indicator is damaged.

Safety filter will become plugged if a leak occurs in the restriction indicator. The restriction indicator will not work when the safety filter is very dirty.

Checking the Safety Filter STEP 1 Close the intake pipe on the air filter with a block of wood.

STEP 2 Have another person help with the following steps.

STEP 3 Pull the stop cable out until the stop cable stops moving. Hold the stop cable in this position until step 12 has been completed.

Remove the air restriction indicator.

STEP 4 STEP 2 Connect the air restriction indicator to a manometer.

Turn and hold the key switch in the START position for 15 seconds.

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STEP 5

STEP 6

If the safety filter is very dirty, the air filter warning lamp will not illuminate.

If the safety filter is very dirty, remove the air cleaner body from the machine and try to clean the safety filter with compressed air. If the safety filter cannot be cleaned, the air cleaner body must be replaced.

2 3

1

4

3

BS96B025

1. Hose 2. Air Cleaner

3. Clamp 4. Air Restriction Indicator Air Cleaner

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1

2

3

4 5

6

7

B871520

1. Safety Filter 2. Body

3. Filter 4. Wing Nut With Seal Air Cleaner

5. Clamp 6. Baffle

7. Dust Cup

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2001-6

SPARK ARRESTER MUFFLER The laws of some states and provinces make it necessary to install a spark arresting muffler on this machine. The spark arresting muffler has a pipe plug located on the bottom of the muffler.

Make sure the replacement muffler is a spark arresting muffler.

Clean the spark arresting muffler every 100 hours of operation.

STEP 1 Remove the pipe plug from the spark arrester muffler.

The pipe plug is made of brass, if a new pipe plug is needed, the new pipe plug MUST be made of brass.

STEP 2 Pull the stop control out.

STEP 3 Have another person use a block of wood to close the outlet of the muffler.

STEP 4 Hold the key switch in the START position for 30 seconds to remove the carbon from the muffler.

STEP 5 Install the pipe plug in the muffler.

STEP 6 Push the stop control in.

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2 1

3

6

7

8 4

BS96B026

5

1. Extension Pipe 2. Clamp

3. Muffler 4. Mounting Clamp

5. Gasket 6. Clamp

Muffler Installation

7. Pipe From Exhaust Manifold 8. Pipe Plug

7

SECTION INDEX - FUEL SYSTEM Section Title Section Number Fuel System and Filters ............................................................................................................................................ 3002

7

3002 FUEL SYSTEM AND FILTERS

3002

Section

3002-2

TABLE OF CONTENTS FILTER REPLACEMENT .............................................................................................................................................. 3 Fuel Filter Installaiton .................................................................................................................................................................... 4 Primer Pump Installaiton ................................................................................................................................................................ 5

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FILTER REPLACEMENT STEP 1

STEP 5

Your machine may look different than shown, the procedure will be the same.

Lubricate the gasket on the new filter with clean engine oil.

Turn the filter clockwise until the gasket makes contact with the filter head. Use your hands to tighten the filter an additional 1/2 to 3/4 of a turn.

STEP 2

IMPORTANT: Do not use a filter wrench to tighten the filter.

STEP 6 Turn the fuel shutoff valve (1) completely counterclockwise to the ON position.

STEP 7 1

BP96C032

Turn the fuel shutoff valve (1) completely to the OFF position.

STEP 3

3

Clean the area around the filter.

4

STEP 4 BP96E012

Make sure there is fuel in the fuel tank. Loosen the air bleed screw (3) and actuate the primer pump (4). Tighten the air bleed screw (3) when clear fuel with no air bubbles flows from the air bleed screw (3).

2

BP96C032

Turn the filter (2) counterclockwise and remove the filter.

NOTE: Do not fill the new filter with fuel before installation.

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3002-4

1

2

1. Fuel Filter

2. Fuel Shutoff Valve Fuel Filter Installation

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3

4

3. Air Bleed Screw

4. Primer Pump Primer Pump Installaiton

7

SECTION INDEX - ELECTRICAL Section Title Section Number Removal and Installation of Electrical Components........................................................................................................ 4000 Electrical Specifications and Troubleshooting................................................................................................................ 4002 Battery ................................................................................................................................................................... 4005

7

Section 4000

4000

REMOVAL AND INSTALLATION OF ELECTRICAL COMPONENTS

4000-2

TABLE OF CONTENTS STARTER ..................................................................................................................................................................

Removal .................................................................................................................................................................

Installation ..............................................................................................................................................................

Stater Installation ...................................................................................................................................................

3 3 4 5

ALTERNATOR ............................................................................................................................................................ 6 Removal ................................................................................................................................................................. 6 Installation .............................................................................................................................................................. 6 DRIVE BELT TENSION ................................................................................................................................................ 8

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information 4000-3

STARTER Removal

STEP 5

STEP 1 Start and run the engine at idle.

STEP 2

BP96C038 Disconnect the seat bar locking mechanism on each side.

STEP 6 BP96C016 Raise the loader lift arms to full height. Have another person install the support strut.

STEP 3 Stop the engine and raise the seat bars.

STEP 4 BP96C039 Use the grab handles and pull the operators compartment all the way forward.

STEP 7

BP96C055 Loosen and remove the bolts, lock washers and flat washers that fasten the operators compartment to the posts on the rear of the machine.

1

H04314

1. Negative Battery Cable Disconnect the negative battery cable (1) from the battery.

STEP 8 Fasten identification tags to the wires at the starter.

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information

4000-4

STEP 9

STEP 4

Disconnect the wires from the starter.

STEP 10 Hold the starter in place and remove the cap screws and lock washers that fasten the starter to the engine. Remove the starter from the engine.

Installation STEP 1 Put the starter in position on the engine. Install the cap screws and lock washers that fasten the starter to the engine.

STEP 2

BP96C039 Use the grab handles and push the operators compartment up and back to the rear of the machine. Carefully lower the ROPS canopy into position.

Connect the wires to the starter.

STEP 5 STEP 3

1 1. Negative Battery Cable Connect the negative battery cable (1) to the battery.

BP96C055

H04314

Install the bolts, lock washers and flat washers that fasten the operators compar tment to the posts on the rear of the machine. Tighten the bolts to 60 to 70 Nm.

STEP 6

BP96C038 Connect the seat bar locking mechanism on each side.

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1

2 BS96E016

1. Starter

2. Cap Screw and Lock Washer

Starter Installation

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4000-6

ALTERNATOR Removal

Installation

STEP 1

STEP 5 Hold the alternator (2) and the guard (4) in position against the engine. Install the cap screw, lock washer, and flat washer (3) at the bottom of the alternator (2).

STEP 6 Install the drive belt (5) on the drive pulley (6) of the alternator.

STEP 7 1

H04314

1. Negative Battery Cable Disconnect the negative battery cable from the battery.

STEP 2 Fasten identification tags to the wires connected to the rear of the alternator. Disconnect the wires.

Install the cap screw, lock washer, and flat washer (1) that fasten the top of the alternator (2) and the guard (4)

STEP 8 Adjust the drive belt tension according to the instructions on page 8.

STEP 9.

Connect the wires to the alternator (2).

STEP 3 Remove the cap screw and flat washer (1) from the top of the alternator (2).

STEP 10 Connect the negative battery cable to the battery.

STEP 4 Loosen and remove the cap screw, lock washer, and flat washer (3) from the bottom of the alternator (2). Remove the guard (4) and the alternator (2).

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1 6

4

2

3 5

00 B877252W 1. Top Cap Screw, Lock Washer, and Flat Washer 2. Alternator

3. Bottom Cap Screw, Lock Washer, and Flat Washer 4. Guard

5. Drive Belt 6. Drive Pulley

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4000-8

DRIVE BELT TENSION Check the tension of a new drive belt after the first two hours of operation and after the first 20 hours of operation with a new machine. Then check the tension of the drive belt every 100 hours of operation.

3

STEP 1 Push the drive belt (1) with approximately 10 kg of force and check the deflection where shown in the photo.

4

STEP 2 The deflection must be 10 to 13 mm.

STEP 3 If the deflection is not correct, loosen the pivot bolt (2) and adjusting bolt (3). Move the top of the alternator (4) as necessary to get the correct deflection.

1

2 B877252W

STEP 4 Tighten the adjusting bolt (3) and the pivot bolt (2).

1. Drive Belt, Check Deflection Here 2. Pivot Bolt

3. Adjusting Bolt 4. Alternator

4002 ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

4002

Section

4002-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 2 ALPHABETICAL INDEX .................................................................................................................................................................. 3 ELECTRICAL CIRCUITS .............................................................................................................................................. 5 TROUBLESHOOTING EXAMPLE .................................................................................................................................. 8 TROUBLESHOOTING .................................................................................................................................................. 9

SPECIFICATIONS Type of system ......................................................................................................................... One 12 volt battery, negative ground System voltage .............................................................................................................................................. Approximately 12 volts Battery Reserve capacity .......................................................................................................................................................... 90 minutes Cold cranking amperes ............................................................................................................................................................. 350 Alternator ............................................................................................................................................................. 12 volt, 30 ampere Starter .......................................................................................................................................... 12 volt 1.4 kW, solenoid actuated Component Specifications

Reading

Fuel level sending unit ........................................................................................................................................ Full - 90 ohms Empty - 0 ohms Hydraulic oil temperature switch .................................................................... To close at 110 ± 3°C on increasing temperature Engine temperature switch ............................................................................. To close at 104 ± 5°C on increasing temperature Glow plug relay ............................................................................................................. Normally open, coil internally grounded Transmission charge pressure .................................................. To close at 483 ± 35 kPa, 5 ± 0.35 bar on decreasing pressure Fuses Alternator to key switch ............................................................................................................................................. 30 ampere Key switch to work lamp switch ................................................................................................................................. 20 ampere Positive post of battery to rear work lamp switch ........................................................................................................ 10 ampere Battery terminal of the starter to electric accessories switch ...................................................................................... 10 ampere Battery terminal of the starter to junction block (1) ..................................................................................................... 20 ampere Junction block to hazard warning switch..................................................................................................................... 35 ampere Road lamp switch to left hand road lamps ................................................................................................................. 7.5 ampere Road lamp switch to right hand road lamps .............................................................................................................. 7.5 ampere Circuit breaker for glow plugs .................................................................................................................................... 40 ampere

4002-3

ALPHABETICAL INDEX A Air Filter Switch ................................................. 14 Alarm Backup.......................................................... 15 Alternator ...................................................... 18 B Backup Alarm.................................................... 15 Backup Alarm Proximity Switch, LH ...................16 Backup Alarm Relay .......................................... 17 Battery .............................................................. 12 Brake Lamp Time Delay Relay........................... 25 Brake Lamp, LH ................................................ 25 Brake Lamp, RH ................................................ 26 Brake Valve Solenoid......................................... 18 Button Horn ............................................................... 9 E Electric Accessories Plug .................................. 20 Engine Oil Pressure Switch ............................... 13 Engine Temperature Switch ............................... 15 F Flasher Lamp, LH Front ..................................... 23 Flasher Lamp, LH Rear ..................................... 22 Flasher Lamp, RH Front .................................... 23 Flasher Lamp, RH Rear..................................... 23 Flasher Unit Hazard Warning ............................................ 22 Turn Signal.................................................... 21 Front Work Lamp, LH........................................... 9 Front Work Lamp, RH ......................................... 9 Fuel Level Sender ............................................. 17 Fuel Shutoff Solenoid ........................................ 17 G Glow Plug Indicator Lamp.................................. 10 Glow Plug Relay................................................ 18 Glow Plugs ........................................................12 H Hazard Warning Flasher Unit............................. 22 Hazard Warning Switch .....................................22

Horn ................................................................. 12 Horn Button ........................................................ 9 Hydraulic Filter Switch ...................................... 14 Hydraulic Oil Temperature Switch ..................... 14 I Instrument Panel .............................................. 11 K Key Switch ....................................................... 10 L Lamp Glow Plug Indicator ...................................... 10 LH Brake ...................................................... 25 LH Front Flasher .......................................... 23 LH Front Road .............................................. 24 LH Front Work ................................................ 9 LH Rear Flasher ........................................... 22 LH Rear Road .............................................. 25 Licenses Plate .............................................. 24 Parking Brake Indicator ................................ 19 Rear Work ..................................................... 11 RH Brake...................................................... 26 RH Front Flasher .......................................... 23 RH Front Road ............................................. 24 RH Front Work................................................. 9 RH Rear Flasher .......................................... 23 RH Rear Road............................................... 26 Turn Signal Indicator ..................................... 21 Lamp Switch, Work ........................................... 10 LH Backup Alarm Proximity Switch ................... 16 LH Brake Lamp ................................................... 5 LH Front Flasher Lamp ..................................... 23 LH Front Road Lamp ........................................ 24 LH Rear Flasher Lamp ..................................... 22 LH Rear Road Lamp ......................................... 25 Licenses Plate Lamp ........................................ 24 P Parking Brake Indicator Lamp ........................... 19 Parking Brake Switch ........................................ 19

4002-4

R Rear Work Lamp ............................................... 11 Rear Work Lamp Switch ................................... 20 Relay Backup Alarm............................................... 17 Brake Lamp Time Delay................................ 25 Glow Plug..................................................... 18 RH Backup Alarm Proximity Switch .................. 16 RH Brake Lamp ................................................ 26 RH Front Flasher Lamp .................................... 23 RH Front Road Lamp........................................ 24 RH Rear Flasher Lamp..................................... 23 RH Rear Road Lamp ........................................ 26 Road Lamp Switch ........................................... 21 Road Lamp, LH Front ....................................... 24 Road Lamp, LH Rear ........................................ 25 Road Lamp, RH Front....................................... 24 Road Lamp, RH Rear ....................................... 26 Rotating Beacon............................................... 20 S Seat Bar Limit Switch ....................................... 19 Sender Fuel Level .................................................... 17 Solenoid Brake Vavle .................................................. 18 Fuel Shutoff.................................................. 17 Starte ................................................................ r 8 Starter and Starter Solenoid ............................. 13 Switch Air filter ........................................................ 14 Engine Oil Pressure ..................................... 13

Engine Temperature...................................... 15 Hazard Warning ............................................ 22 Hydraulic Filter ............................................. 14 Hydraulic Oil Temperature............................. 14 Key............................................................... 10 LH Backup Alarm Proximity .......................... 16 Parking Brake ............................................... 19 Rear Work Lamp........................................... 20 RH Backup Alarm Proximity.......................... 16 Road Lamp................................................... 21 Seat Bar Limit............................................... 19 Transmission Charge Pressure ..................... 13 Turn Signal ................................................... 25 Work Lamp ................................................... 10 T Transmission Charge Pressure Switch ..............

Turn Signal Flasher Unit ...................................

Turn Signal Indicator Lamp ...............................

Turn Signal Switch ............................................

13 21 21 25

W Work Lamp Switch, Rear .................................. 20

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ELECTRICAL CIRCUITS NO. 1 2 3 4 5 6 7 7A 7B 8 9 10 11 12 12A 12B 12C 12D 12E 13 13A 14 14A 14B 14C 14D 14E 15 16A 16B 16C 16D 16E 16F 16G 16H 17 22 22A 22B 22C 22D 22E

GA. 18 18 20 20 20 20 10 10 10 20 20 14 20 12 14 18 16 18 18 14 14 10 16 16 18 16 16 14 10 10 10

16 16 16 12 18 18 16 16 16 16

COLOR Red Black/White Yellow/Tan Yellow Yellow/Green Yellow/Black Red Red Red Yellow/Gray Yellow/Pink Red Yellow/Brown Black Black Black Black Black Black White/Tan Red Red Orange Orange Orange Orange Orange Red Red/Orange Red Red Black Black Pink Red Red White Pink Pink Red Red Red Red

FROM: Key Switch Key Switch Instrument Panel T11 Instrument Panel T1 Instrument Panel T8 Instrument Panel T2 Connector E 30 Ampere Fuse Alternator (Bat Terminal) Instrument Panel T12 Instrument Panel T5 Key Switch Instrument Panel T3 Fuel Shutoff Solenoid Work Lamps LH Front Work Lamp and Air Filter Switch RH Front Work Lamp Instrument Panel Glow Plug Indicator Lamp Key Switch (Ign Terminal) Connector E Starter Solenoid Key Switch (Ign Terminal) Work Lamp Switch LH Front Work Lamp Work Lamp Switch 20 Amp Fuse Key Switch (Heat Terminal) Starter Solenoid 40 Ampere Circuit Breaker Glow Plug Relay Road Lamp Switch Connector Rear Work Lamp Junction Block (6) Positive Post of Battery Rear Work Lamp Switch Starter Motor Key Switch (Ign Terminal) Connector A Key Switch (Ign Terminal) Key Switch (Ign Terminal) Key Switch (Ign Terminal) Key Switch (Ign Terminal)

TO: Instrument Panel T4 Alternator Hydraulic Filter Switch Engine Oil Pressure Switch Engine Temperature Switch Hydraulic Oil Temperature Switch Key Switch (Bat Terminal) Connector E 30 Ampere Fuse Air Filter Switch Transmission Charge Pressure Switch Starter Solenoid Fuel Level Sender Ground Ground Ground Ground Ground Ground Connector E Fuel Shutoff Solenoid (Hold Terminal) Alternator (Bat Terminal) 20 Amp Fuse LH Front Work Lamp Connector RH Front Work Lamp Work Lamp Switch Glow Plug Relay 40 Ampere Circuit Breaker Glow Plug Relay Glow Plugs Work Lamp Harness Connector Connector for Front Work Lamps Front Work Lamps Rear Work Lamp Switch Rear Work Lamp Fuel Shutoff Solenoid (Pull Terminal) Connector A Horn Button Backup Alarm Relay LH Proximity Switch RH Proximity Switch Backup Alarm (+)

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4002-6 NO.

GA.

COLOR

FROM:

TO:

23A 23B 24 25 26 27 28 29 29A 30 31 32 33 34 34A 35 36 36A 37 38 39 39A 40 40A 40B 40C 41 41A 41B 41C 42 42A 42B 43 43A

18 18 16 16 16 16 16 16 18 18 18 18 18 18 18 16 16 16 16 16 16 18 18 18 18 18 18 18 18 16 16 16 16 16

Pink Pink Red/White Pink Red/Purple Pink/Brown Purple/Black Black Black Red Brown Green/White Green Red/White Black Black Red Red Red Black Red Red Green Green Green White Blue Green/White Green/White Green/White Brown Black Black Black Black Black

Horn Button Connector Key Switch (Heat Terminal) Key Switch (Ign Terminal) Backup Alarm (-) Backup Alarm Relay (T85) LH Proximity Switch (-) RH Proximity Switch (-) Backup Alarm Relay (T30) Ign Switch (Ign Terminal) Seat Bar Limit Switch Parking Brake Switch Seat Bar Limit Switch Parking Brake Switch Parking Brake Solenoid Parking Brake Indicator Lamp Battery Terminal (+) Fuse, 10 Ampere Electrical Accessories Switch Electrical Accessories Plug Junction (1) Fuse, 20 Ampere Junction Block (2) Connector Connector G Turn Signal Switch Junction Block (3) Connector Connector H Turn Signal Switch Connector Connector G Ground Terminals for LH Road Lamps Connector H Ground Terminals for RH Road Lamps

Connector Horn Glow Plug Indicator Lamp Auxiliary Power Backup Alarm Relay (T87) LH Proximity Switch (C) RH Proximity Switch (C) Ground Ground Seat Bar Limit Switch Parking Brake Indicator Lamp Parking Brake Indicator Lamp Parking Brake Switch Parking Brake Solenoid Ground Ground Fuse, 10 Ampere Electrical Accessories Switch Electrical Accessories Plug Ground Fuse, 20 Ampere Starter Solenoid (Battery Terminal) Connector Connector G LH Flasher Lamp Junction Block (2) Connector Connector H RH Flasher Lamp Junction Block (3) Junction Block (4), Ground Connector Connector G Junction Block (4, Ground) Connector H

43B 43C 44 44A 44B 45 45A 45B 45C 45D

16 16 18 18 18 18 18 18 18 18

Black Black Red Red Red Red Red Red Red Red

Connector K Connector J Junction Block (6) Fuse, 7.5 Ampere Connector G Junction Block (6) Fuse, 7.5 Ampere Connector H Connector H Connector J

Connector H Connector K Fuse, 7.5 Ampere Connector G LH Road Lamps Fuse, 7.5 Ampere Connector H RH Road Lamps Connector J Connector K

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-7

NO.

GA.

COLOR

FROM:

TO:

45E 46 46A 46B 46C 47 47A 47B 48 49 49A 50 51 51A 52 52A 53 53A 54 55 56 57 58 59 59A

18 18 18 18 18

Green/Yellow Gray Gray Gray Gray Purple Purple Green/Red Greed/Red Green/White Black Black Purple Red

Junction Block (7) Connector H Connector J Connector J Connector G Junction Block (1) Fuse, 35 Ampere Flasher Unit Hazard Warning Switch Junction Block (3) Hazard Warning Switch Indicator Lamp Junction Block (4), Ground Turn Signal Indicator Lamp Junction Block (1) Junction Block (1) Driving Lamp Switch Hazard Waring Switch Turn Signal Flasher Unit Connector J Connector J Time Delay Relay LH Limit Switch RH Limit Switch Connector K License Plate Lamp

Turn Signal Switch RH Brake Lamp Connector H Connector G LH Brake Lamp Fuse, 35 Ampere Flasher Unit Hazard Warning Switch Junction Block (2) Hazard Warning Switch Junction Block (4), Ground Ground Junction Block (7) Turn Signal Indicator Lamp Road and Work Lamp Switch Junction Block (6) Turn Signal Flasher Unit Junction Block (7) Time Delay Relay LH Limit Switch Connector M RH Limit Switch Time Delay Relay License Plate Lamp Connector K

Green/Brown 18 18 16 18 18 18 18

Gray Red Black Blue Green Red Black

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-8

TROUBLESHOOTING EXAMPLE Number and component correspond with the number and component on the schematic.

Location to connect leads of electrical tester.

What electrical test should indicate.

1

One or more possible reasons for an indication which is not correct.

Starter and Starter Solenoid

Check Points

Reading

Possible Cause of Bad Reading

Battery terminal of starter solenoid to ground

12 volts

Check the battery cable to the positive post of the battery.

NOTE: Have another person hold the key switch in the START position.

Terminal for wire 21B to ground

12 volts

Check the starter relay (7), neutral start relay (9) and the key switch (6).

NOTE: If the readings are good, see Section 4004 and check the starter.

This statement assumes that all mechanical, hydraulic, and other electrical problems have been solved at this point.

This number indicates the number of the component on the electrical schematic.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-9

TROUBLESHOOTING

1

RH Front Work Lamp

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 12C to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Turn the lamp switch to ON. Terminal for wire 14D to ground

12 volts

2

Check the circuit between the RH lamp and the lamp switch (4). Also check the lamp switch (4).

LH Front Work Lamp

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 12B to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Turn the lamp switch to ON. Terminal for wire 14B to ground

12 volts

Check the circuit between the LH lamp and the lamp switch (4). Also check the lamp switch (4).

3 Check Points

Horn Button

Reading

Possible Cause of Bad Reading

12 volts

Check the circuit between the horn button and the key switch (6).

Also check the key switch (6).

NOTE: Turn the key switch to ON. Terminal for wire 22 to ground

NOTE: Have another person push down and hold the horn button.

Terminal for wire 23A to ground

12 volts

Bad horn button.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-10

4 Check Points

Work Lamp Switch

Reading

Possible Cause of Bad Reading

12 volts

Check the circuit between the lamp switch and key switch (6). Also check the 20 ampere fuse and key switch (6).

NOTE: Turn the key switch to ON. Terminal for wire 14E to ground

NOTE: Turn the work lamp switch to ON. Terminal for wire 14B or 14D to ground

12 volts

5

Bad work lamp switch.

Glow Plug Indicator Lamp

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 12E to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

12 volts

Check the circuit between the glow plug indicator lamp and the key switch (6). Also check the key switch (6).

NOTE: Turn the key switch to HEAT. Terminal for wire 24 to ground

NOTE: If the readings are good, replace the glow plug indicator lamp.

6

Key Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 7 to ground

12 volts

Bad 30 ampere fuse. Check the circuit between the key switch and the alternator (25). Also check the alternator (25).

NOTE: Disconnect the connector from the key switch. Make sure the key switch is in the OFF position.

Between any two terminals of the key switch

Open

Bad key switch.

NOTE: Turn the key switch to the ON position.

Between the BAT and IGN terminals of the key switch

Continuity

Bad key switch.

NOTE: Hold the key switch in the START position.

Between the BAT and ST terminals of the key switch

Continuity

Bad key switch.

Between the BAT and IGN terminals of the key switch

Continuity

Bad key switch.

NOTE: Hold the key switch in the HEAT position.

Between the BAT and HEAT terminals of the key switch

Continuity

Bad key switch.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-11

7

Rear Work Lamp

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 16E to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Turn the key switch to ON. Turn the rear work lamp switch to ON. Terminal for wire 16H to ground

12 volts

8 Check Points

Reading

Check the circuit between the rear lamp and the rear lamp switch (31). Also check the rear lamp switch (31).

Instrument Panel Possible Cause of Bad Readings

NOTE: Disconnect the connector from the instrument panel. Turn the key switch to ON. Terminal T4 in connector to ground

12 volts

Check the circuit between the connector and the key switch (6). Also check the key switch (6).

Terminal T7 in connector to ground

Continuity

Check the circuit between the connector and chassis ground.

Terminal T11 in connector to ground

Continuity

Check the circuit between the connector and the hydraulic filter switch (17). Also check the hydraulic filter switch (17).

Terminal T1 in connector to ground

Continuity

Check the circuit between the connector and the engine oil pressure switch (14). Also check the engine oil pressure switch (14).

Terminal T8 in connector to ground

Continuity

Check the circuit between the connector and the engine temperature switch (18). Also check the engine temperature switch (18).

Terminal T2 in connector to ground

Continuity

Check the circuit between the connector and the hydraulic oil temperature switch (16). Also check the engine temperature switch (16).

Terminal T12 in connector to ground

Continuity

Check the circuit between the connector and the air filter switch (15).

Also check the air filter switch (15).

Terminal T5 in connector to ground

Continuity

Check the circuit between the connector and the transmission charge pressure switch (13). Also check the transmission charge pressure switch (13).

Terminal T3 in connector to ground

Continuity

Check the circuit between the connector and the fuel level sender (24). Also check the fuel level sender (24).

NOTE: If the readings are good, replace the instrument panel.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-12

9

Horn

Check Points

Reading

Possible Cause of Bad Readings

Ground terminal to ground

Continuity

Bad ground connection.

NOTE: Turn the key switch to the ON position. Have another person hold down the horn button.

Terminal for wire 23B to ground

12 volts

Check the circuit between the horn and the horn button (3). Also check the horn button (3).

NOTE: If the readings are correct and the horn does not work, replace the horn.

10 Check Points

Reading

Glow Plugs Possible Cause of Bad Readings

NOTE: Have another person put the key switch in the HEAT position.

Terminal for wire 16C to ground at each glow plug

12 volts

Check the circuit between the glow plug and the glow plug relay (26).

Also check the glow plug relay (26).

NOTE: Disconnect the wire at the terminal on each glow plug.

Between the terminal on the glow plug and engine ground next to the glow plug

1.0 to 1.2 ohms

11

Bad glow plug

Battery

NOTE: The battery must be at full charge and all connections clean and tight before testing. Use a multimeter for the tests. A battery with full charge should be between 12.5 and 12.6 volts. See Section 4005 and check the battery.

12

Starter and Starter Solenoid

Check Points

Reading

Possible Cause of Bad Readings

Battery terminal of starter solenoid to ground

12 volts

Check the battery cable between the starter and the positive post of the battery.

NOTE: Disconnect the electrical connector from the fuel shutoff solenoid. Have another person hold the key switch in the START position. (The starter motor will turn when the key switch is in the START position.)

Start terminal of starter solenoid to ground

12 volts

Check the circuit between the starter solenoid and the key switch (6).

Also check the key switch (6).

NOTE: If the readings are good, see the Kubota Engine Manual and check the starter and starter solenoid.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-13

13

Transmission Charge Pressure Switch

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the transmission charge pressure switch and the engine block

Continuity

Bad ground connection between the transmission charge pressure switch and the engine block.

NOTE: Disconnect wire 9 from the transmission charge pressure switch. Turn the key switch to ON. Terminal for wire 9 to ground

6.5 - 7.5 volts

Check the circuit between the transmission charge pressure switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: If the readings are good, replace the transmission charge pressure switch.

14

Engine Oil Pressure Switch

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the engine oil pressure switch and the engine block

Continuity

Bad ground connection between the engine oil pressure switch and the engine block.

NOTE: Disconnect wire 4 from the engine oil pressure switch. Turn the key switch to ON. Terminal for wire 4 to ground

6.5 - 7.5 volts

Check the circuit between the engine oil pressure switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: If the readings are good, replace the engine oil pressure switch.

15

Air Filter Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 12B to ground

Continuity

Bad ground connection.

6.5 - 7.5 volts

Bad circuit between the air filter restriction switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: Turn the key switch to ON. Terminal for wire 8 to ground

NOTE: If the readings are good, replace the air filter switch.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-14

16

Hydraulic Oil Temperature Switch

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the hydraulic oil temperature switch and ground

Continuity

Bad ground connection between the hydraulic oil temperature switch and ground.

6.5 - 7.5 volts

Check the circuit between the hydraulic oil temperature switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: Turn the key switch to ON. Terminal for wire 6 to ground

NOTE: If the readings are good, replace the hydraulic oil temperature switch.

17

Hydraulic Filter Switch

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the hydraulic filter switch and ground

Continuity

Bad ground connection between the hydraulic filter switch and ground.

6.5 - 7.5 volts

Check the circuit between the hydraulic filter switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: Turn the key switch to ON. Terminal for wire 3 to ground

NOTE: If the readings are good, replace the hydraulic filter switch.

18

Engine Temperature Switch

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the engine temperature switch and the engine block

Continuity

Bad ground connection.

6.5 - 7.5 volts

Check the circuit between the engine temperature switch and the instrument panel (8). Also check the instrument panel (8).

NOTE: Turn the key switch to ON. Terminal for wire 5 to ground

NOTE: If the readings are good, replace the engine temperature switch.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-15

19 Check Points

Backup Alarm (Optional)

Reading

Possible Cause of Bad Reading

12 volts

Check the circuit between the backup alarm and the key switch (6).

Also check the key switch (6).

NOTE: Turn the key switch to ON. Terminal for wire 22E to ground

NOTE: Move both loader control levers rearward.

Terminal for wire 26 to ground

Continuity

Check the circuit between the backup alarm and the backup alarm relay (22). Also check the backup alarm relay (22).

NOTE: If the readings are good, replace the backup alarm.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-16

20 and 21

RH Backup Alarm Proximity Switch and LH Backup Alarm Proximity Switch

Check Points

Reading

Possible Cause of Bad Readings

NOTE: See Section 9001. Make sure the proximity switch is adjusted correctly.

NOTE: Disconnect the harness from the connectors on the backup alarm proximity switches.

Terminal for wire 29 in the harness connector to ground

Continuity

Bad ground circuit.

Terminal for wire 22D in the harness connector to ground

12 volts

Check the circuit between the RH backup alarm proximity switch and the key switch (6). Also check the key switch (6).

Terminal for wire 22C in the harness connector to ground

12 volts

Check the circuit between the LH backup alarm proximity switch and the key switch (6). Also check the key switch (6).

Terminal for wire 27 in the harness connector to ground

12 volts

Check the circuit between the LH backup alarm proximity switch and the backup alarm relay (22). Also check the backup alarm relay (22).

Terminal for wire 28 in the harness connector for the RH backup alarm proximity switch to terminal for wire 28 in the harness connector for the LH backup alarm proximity switch

Continuity

Bad circuit between the RH backup alarm proximity switch and the LH backup alarm proximity switch.

NOTE: Turn the key switch to ON.

NOTE: The following checks will be made at the connectors on the backup alarm proximity switches.

Check between the terminal for the red wire and the terminal for the white wire in the switch connectors.

Continuity

Bad backup alarm proximity switch.

Check between the terminal for the black wire and the terminal for the white wire in the switch connectors.

Open

Bad backup alarm proximity switch.

NOTE: Select the loader control lever for the backup alarm proximity switch being checked. Move the loader control lever rearward.

Check between the terminal for the red wire and the terminal for the white wire in the switch connectors.

Open

Bad backup alarm proximity switch.

Check between the terminal for the black wire and the terminal for the white wire in the switch connectors.

Continuity

Bad backup alarm proximity switch.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-17

22 Check Points

Backup Alarm Relay

Reading

Possible Cause of Bad Readings

NOTE: Check the RH Backup Alarm Proximity Switch (20) and LH Backup Alarm Proximity Switch (21) before doing this procedure.

Terminal for wire 29A to ground

Continuity

Bad ground circuit.

NOTE: Disconnect the electrical connector from the LH backup alarm proximity switch (21). Turn the key switch to ON. Terminal for wire 22B to ground

12 volts

Check the circuit between the backup alarm relay and the key switch (6). Also check the key switch (6).

Terminal for wire 27 to ground

12 volts

Bad backup alarm relay.

NOTE: Connect the electrical connector for the LH backup alarm proximity switch (21). Disconnect wire 26 from the backup alarm (19). Move both loader control levers rearward.

Terminal for wire 26 to ground

Continuity

23

Bad backup alarm relay.

Fuel Shutoff Solenoid

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the fuel shutoff solenoid and the engine block.

Continuity

Bad ground connection.

12 volts

Check the circuit between the fuel shutoff solenoid and the key switch (6). Also check the key switch (6).

NOTE: Turn the key switch to ON. Terminal for wire 13A to ground

NOTE: Disconnect the connector from the fuel shutoff solenoid. Turn the key switch to the START position. (Starter will turn when holding the key switch in the START position.

Terminal for wire 17 to ground

12 volts

Check the circuit between the fuel shutoff solenoid and the starter solenoid (12). Also check the starter solenoid (12).

NOTE: If the readings are good, replace the fuel shutoff solenoid.

24

Fuel Level Sender

Check Points

Reading

Possible Cause of Bad Readings

Check between the housing of the fuel level sender and the machine frame.

Continuity

Bad ground connection between the fuel level sender and the machine frame.

6.5 - 7.5 volts

Check the circuit between the fuel level sender and the instrument panel (8). Also check the instrument panel (8).

NOTE: Turn the key switch to ON. Terminal for wire 11 to ground

NOTE: If the readings are good, replace the fuel level sender.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-18

25

Alternator

Check Points

Reading

Possible Cause of Bad Readings

Between the housing of the alternator and ground

Continuity

Bad ground connection.

Terminal for wire 14 to ground.

12 volts

Check wire 14 between the starter terminal and the alternator.

Approximately 12 volts

Check the circuit between the alternator and the key switch (6). Also check the key switch (6).

NOTE: Turn the key switch to ON. Terminal for wire 2 to ground

NOTE: If the readings are good see the Kubota Engine Manual and repair the alternator.

26

Glow Plug Relay

Check Points

Reading

Possible Cause of Bad Readings

Between ground terminal of glow plug relay and ground

Continuity

Bad ground connection between the glow plug relay and ground.

Terminal for wire 16B to ground

12 volts

Check the circuit between the glow plug relay through the 40 ampere circuit breaker to battery terminal of the starter (12). Also check the 40 ampere circuit breaker and the starter (12).

NOTE: Turn the key switch to HEAT position.

Terminal for wire 15 to ground

12 volts

Check the circuit between the glow plug relay and the key switch (6).

Also check the key switch (6).

Terminal for wire 16C to ground

12 volts

Bad glow plug relay.

NOTE: If the readings are good, replace the glow plug relay.

27

Brake Valve Solenoid (Disengages Brake When Energized)

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 34A to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to ON. With the seat bars in the operating position and the parking brake switch in the released position.

Terminal for wire 34 to ground

12 volts

Check the circuit between the brake valve solenoid and the parking brake switch (29). Also check the parking brake switch (29).

NOTE: If the readings are good, replace the brake valve solenoid.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-19

28

Seat Bar Limit Switch (Non-Operational Position)

Check Points

Reading

Possible Cause of Bad Readings

NOTE: Turn the key switch to ON. Make sure the seat bars are in the operating position.

Terminal for wire 30 to ground

12 volts

Check the circuit between the seat bar limit switch and the key switch (6). Also check the key switch (6).

Terminal for wire 33 to ground

12 volts

Bad seat bar limit switch.

Terminal for wire 31 to ground

0 volts

Bad seat bar limit switch.

Terminal for wire 31 to ground

12 volts

Bad seat bar limit switch.

Terminal for wire 33 to ground

0 volts

Bad seat bar limit switch.

NOTE: Move the seat bars up.

29 Check Points

Parking Brake Switch (Engaged Position) Reading

Possible Cause of Bad Readings

NOTE: Turn the key switch to ON. Make sure the seat bars are in the operating position.

Terminal for wire 33 to ground

12 volts

Check the circuit between the parking brake switch and the seat bar limit switch (28). Also check the seat bar limit switch (28).

NOTE: With the parking brake switch in the disengaged position.

Terminal for wire 34 to ground

12 volts

Bad parking brake switch.

NOTE: With the parking brake switch in the engaged position.

Terminal for wire 32 to ground

12 volts

30

Bad parking brake switch.

Parking Brake Indicator Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for wire 35 to ground

Continuity

Bad ground circuit.

NOTE: Turn the key switch to ON. Put the seat bars in the park (non-operating) position.

Terminal for wire 31 to ground

12 volts

Check the circuit between the parking brake indicator lamp and the seat bar limit switch (28). Also check the seat bar limit switch (28).

NOTE: Put the seat bars in the operating position. Make sure the parking brake switch in the engaged position.

Terminal for wire 32 to ground

12 volts

Check the circuit between the parking brake indicator lamp and the parking brake switch (29). Also check the parking brake switch (29).

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-20

31

Rear Work Lamp Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 16H to ground

12 volts

Bad 10 ampere fuse. Check the circuit between the rear work lamp switch and the battery (11). Also check the battery (11).

NOTE: Put the rear work lamp in the ON position.

Terminal for wire 16J to ground

12 volts

32

Bad rear work lamp switch.

Electric Accessories Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 36A to ground

12 volts

Bad 10 ampere fuse. Check the circuit between the electric accessories switch and the battery (11). Also check the battery (11).

NOTE: Put the electric accessories switch in the ON position.

Terminal for wire 37 to ground

12 volts

33

Bad electric accessories switch.

Electric Accessories Plug

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 38 to ground

Continuity

Bad ground circuit.

NOTE: Put the electric accessories switch in the ON position.

Terminal for wire 37 to ground

12 volts

34

Bad circuit between the electric accessories plug and the electric accessories switch (32). Also check the electric accessories switch (32).

Rotating Beacon

Check Points

Reading

Possible Cause of Bad Readings

Terminal for black wire to ground

Continuity

Bad ground circuit.

Bulb

Good

Bad bulb.

NOTE: Put the electric accessories switch in the ON position.

Terminal for red wire to ground

12 volts

Bad circuit between the rotating beacon and the electric accessories plug (33). Also check the electric accessories plug (33).

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-21

35 Check Points

Turn Signal Flasher Unit

Reading

Possible Cause of Bad Readings

NOTE: Disconnect wire 53 from the turn signal flasher.

Terminal for wire 53 to ground

12 volts

Bad 20 ampere fuse. Bad circuit between the turn signal flasher unit and the positive post on the starter (12). Also check the starter (12).

NOTE: Connect wire 53 to the turn signal flasher. Disconnect wire 53A from the turn signal flasher.

Terminal on flasher for wire 53A to ground

Intermittent 12 volts

36

Bad turn signal flasher.

Road Lamp Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 52 to ground

12 volts

Bad 20 ampere fuse. Bad circuit between the road lamp flasher unit and the positive post on the starter (12). Also check the starter (12).

NOTE: Put the road lamp switch in the ON position.

Terminal for wire 52A to ground

12 volts

37

Bad road lamp switch.

Turn Signal Indicator Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for wire 51A to ground

12 volts

Bad 20 ampere fuse. Bad circuit between the road lamp flasher unit and the positive post on the starter (12). Also check the starter (12).

NOTE: Disconnect wires from the turn signal indicator lamp.

Between the terminals for the turn signal indicator lamp.

Continuity

Bad turn signal indicator lamp.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

4002-22

38

Hazard Warning Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 47B to ground

Intermittent 12 volts

Bad circuit between the hazard warning switch and the hazard warning flasher unit (39). Also check the hazard warning flasher unit (39).

NOTE: Put the hazard warning switch in the ON position.

Terminal for wire 48 to ground.

Intermittent 12 volts

Bad hazard warning switch.

Terminal for wire 49 to ground

Intermittent 12 volts

Bad hazard warning switch.

Terminal for wire 49A to ground

Continuity

Bad ground circuit for the hazard warning switch indicator lamp.

39

Hazard Warning Flasher Unit

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 47A to ground

12 volts

Bad 35 ampere fuse or bad 20 ampere fuse. Bad circuit between the hazard warning switch and the positive post on the starter (12). Also check the starter (12).

Terminal for wire 47B to ground

Intermittent 12 volts

Bad hazard warning flasher unit.

40

LH Rear Flasher Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the hazard warning switch in the ON position.

Terminal for green wire to ground

12 volts

Bad circuit between the LH rear flasher lamp and the hazard warning switch (38). Also check the hazard warning switch (38).

NOTE: Put the hazard warning switch in the OFF position. Hold the turn signal switch for a left turn.

Terminal for green wire to ground

12 volts

Bad circuit between the LH rear flasher lamp and the turn signal flasher unit (35). Also check the turn signal flasher unit (35).

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 4002-23

41

LH Front Flasher Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the hazard warning switch in the ON position.

Terminal for wire 40B to ground

12 volts

Bad circuit between the LH front flasher lamp and the hazard warning switch (38). Also check the hazard warning switch (38).

NOTE: Put the hazard warning switch in the OFF position. Hold the turn signal switch for a left turn.

Terminal for wire 40B to ground

12 volts

42

Bad circuit between the LH front flasher lamp and the turn signal flasher unit (35). Also check the turn signal flasher unit (35).

RH Rear Flasher Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the hazard warning switch in the ON position.

Terminal for green wire to ground

12 volts

Bad circuit between the RH rear flasher lamp and the hazard warning switch (38). Also check the hazard warning switch (38).

NOTE: Put the hazard warning switch in the OFF position. Hold the turn signal switch for a right turn.

Terminal for green wire to ground

12 volts

43

Bad circuit between the RH rear flasher lamp and the turn signal flasher unit (35). Also check the turn signal flasher unit (35).

RH Front Flasher Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the hazard warning switch in the ON position.

Terminal for wire 41B to ground

12 volts

Bad circuit between the RH front flasher lamp and the hazard warning switch (38). Also check the hazard warning switch (38).

NOTE: Put the hazard warning switch in the OFF position. Hold the turn signal switch for a left turn.

Terminal for wire 41B to ground

12 volts

Bad circuit between the RH front flasher lamp and the turn signal flasher unit (35). Also check the turn signal flasher unit (35).

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4002-24

44

RH Front Road Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for wire 43A to ground

Continuity

Bad ground circuit.

NOTE: Put the road lamp switch in the ON position.

Terminal for wire 45B to ground

12 volts

45

Bad 7.5 ampere fuse. Bad circuit between the RH front road lamp and the road lamp switch (36). Also check the road lamp switch (36).

LH Front Road Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the road lamp switch in the ON position.

Terminal for wire 44B to ground

12 volts

46

Bad 7.5 ampere fuse. Bad circuit between the LH front road lamp and the road lamp switch (36). Also check the road lamp switch (36).

Licenses Plate Lamp

Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for wire 59A to ground

Continuity

Bad ground circuit.

NOTE: Put the road lamp switch in the ON position.

Terminal for wire 59 to ground

12 volts

Bad 7.5 ampere fuse. Bad circuit between the LH front road lamp and the road lamp switch (36). Also check the road lamp switch (36).

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47

Turn Signal Switch

Check Points

Reading

Possible Cause of Bad Readings

Terminal for wire 45E to ground

Intermittent 12 volts

Bad circuit between the turn signal switch and the turn signal flasher unit (35). Also check the turn signal flasher unit (35).

NOTE: With the hazard warning switch in the OFF position. Hold the turn signal switch for a left turn.

Terminal for wire 40C to ground

Intermittent 12 volts

Bad turn signal switch.

NOTE: Hold the turn signal switch for a right turn.

Terminal for wire 41C to ground

48

Intermittent 12 volts

Bad turn signal switch.

Brake Lamp Time Delay Relay (Italian Machines Only)

49

LH Rear Road Lamp and LH Brake Lamp (Italian Machines Only) Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the road lamp switch in the ON position.

Terminal for red wire to ground

12 volts

Bad 7.5 ampere fuse. Bad circuit between the LH rear road lamp and the road lamp switch (36). Also check the road lamp switch (36).

For Italian Machines Only: NOTE: Move the control levers all the way forward and then to the NEUTRAL position.

Terminal for wire 46C to ground

12 volts for approximately 30 seconds

Bad circuit between the LH brake lamp and the brake lamp time delay relay (48). Also check the brake lamp time delay relay (48).

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4002-26

50

RH Rear Road Lamp and RH Brake Lamp (Italian Machines Only) Check Points

Reading

Possible Cause of Bad Readings

Bulb

Good

Bad bulb.

Terminal for black wire to ground

Continuity

Bad ground circuit.

NOTE: Put the road lamp switch in the ON position.

Terminal for red wire to ground

12 volts

Bad 7.5 ampere fuse. Bad circuit between the RH rear road lamp and the road lamp switch (36). Also check the road lamp switch (36).

For Italian Machines Only: NOTE: Move the control levers all the way forward and then to the NEUTRAL position.

Terminal for wire 46 to ground

12 volts for approximately 30 seconds

Bad circuit between the RH brake lamp and the brake lamp time delay relay (48). Also check the brake lamp time delay relay (48).

Section 4005

4005

BATTERY

4005-2

TABLE OF CONTENTS SAFETY RULES .......................................................................................................................................................... 3 MAINTENANCE .......................................................................................................................................................... 4 Electrolyte Level ...................................................................................................................................................... 4 Inspecting and Cleaning a Battery .............................................................................................................................. 4 NONSPILL CAPS ........................................................................................................................................................ 5 BATTERY TEST ..........................................................................................................................................................

Visual Checks .........................................................................................................................................................

Specific Gravity Check ..............................................................................................................................................

Capacity (Load) Test ................................................................................................................................................

6 6 6 7

CHARGING A BATTERY .............................................................................................................................................. 8 CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES ............................................................................................ 8 CHARGING GUIDE FOR BATTERIES OTHER THAN MAINTENANCE FREE BATTERIES ............................................................................................................................... 9 PREPARING A DRY CHARGED BATTERY FOR USE ....................................................................................................... 9

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SAFETY RULES

!

WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-3A

! !

!

!

WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently charged.

13-8A

WARNING: Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect the ground cable last when the battery cables are connected to the battery.

47- 55A

WA R N I N G : S o m e b a t t e r i e s h a v e a ventilation tube. If there is battery acid in the ventilation tube, this battery acid can be released when the battery is turned upside down. If you turn the battery upside down, make sure that the end of the ventilation tube is away from you and away from any other people in the area. Battery acid can cause severe burns.

48-57B

!

WARNING: If the battery(ies) in this machine must have nonspill caps, do not operate the machine if the nonspill caps do not work correctly, or if the nonspill caps are not in place.

48-99A

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL - Flush with water. INTERNAL Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area.

Always shield eyes when working near batteries. Keep out of reach of children.

D-47-53

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4005-4

MAINTENANCE Electrolyte Level If the battery is a maintenance free battery, check the level of the electrolyte every 1000 hours of operation or six months, whichever occurs first. For all other batteries, check the level of the electrolyte every 250 hours of operation.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery.

If the center part of the decal has been removed for access to the battery caps, it is possible that the words Maintenance Free have been removed from the decal.

Check the level of the electrolyte more often during hot weather. The use of a large amount of water by the battery can be caused by high battery temperature or a voltage regulator setting that is too high. Keep the electrolyte level above the top of the plates in the battery at all times to prevent damage to the battery.

NOTE: On maintenance free batteries it is necessary to remove the center part of the decal for access to the battery caps. Do not discard the center part of the decal.

Install the center part of the decal after the battery caps have been installed.

If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is just below the cell opening. Do not add more water than is needed. Too much water can cause bad performance, a short service life, and corrosion around the battery.

NOTE: Add water only. DO NOT add electrolyte.

Inspecting and Cleaning a Battery If damage causes an electrolyte leak, replace the battery.

If the battery in your machine has nonspill caps, see Nonspill Caps on page 4005-4 and check the condition of the nonspill caps. See Specifications in Section 4002 to find if the battery in your machine must have nonspill caps.

Inspect the battery at regular intervals for dirt, corrosion, and damage. Electrolyte and dirt on the top of the battery can cause the battery to discharge by making a passage for the current to flow.

If the battery must be cleaned, remove the battery from the battery carrier and clean the battery, cable terminals, and the battery carrier. When available, use Case Battery Saver and cleaner according to the instructions on the container. Case Battery Saver and Cleaner also helps prevent corrosion. If Case Battery Saver and Cleaner is not available, use baking soda and water as a cleaner. DO NOT permit any type of cleaner to enter the cells of the battery.

Install the battery in the machine and make sure the fasteners are tight. Apply Case Battery Saver and Cleaner or Urethane Seal Coat to the cable ter minals to prevent corrosion. See the Parts Counter Catalog. DO NOT apply grease.

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NONSPILL CAPS See Specifications in Section 4002 to find if the battery(ies) in your machine must have nonspill caps.

!

WARNING: If the battery(ies) in this machine must have nonspill caps, do not operate the machine if the nonspill caps do not work correctly, or if the nonspill caps are 48-99A not in place.

Do not operate the machine if the nonspill caps do not work correctly or if the nonspill caps are not in place. Nonspill caps prevent electrolyte leakage which can cause personal injury and damage to the machine if the machine turns over in an accident.

The nonspill caps have a valve with a stem made of lead and rubber. When the nonspill cap is turned upside down, the weight of the lead holds the rubber stem against the breather hole, preventing the loss of electrolyte.

If the breather hole and valve are closed by foreign material, pressure in the battery can become high enough to break the case of the battery. Always check the breather hole for foreign material when you check the electrolyte level. If there is foreign material over the breather hole, turn the nonspill cap upside down and clean the nonspill cap. Move the nonspill cap up and down rapidly. You must be able to hear the valve, wash the nonspill cap and loosen the valve. Move the nonspill cap up and down rapidly to remove the water.

When you remove a nonspill cap, check the condition of the rubber gasket. If the rubber gasket is gone or is damaged, install a new nonspill cap.

Missing or broken nonspill caps MUST be replaced with new nonspill caps. DO NOT use any other type of cap to replace nonspill cap.

When you install a new battery, the new battery MUST have nonspill caps. You can use the nonspill caps from the old battery if the nonspill caps are in good condition.

B800305M

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4005-6

BATTERY TEST NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.

1

2

Visual Checks 1. Make sure the cable connections are clean and tight.

Clean foreign material from the top of the battery.

2. Inspect the battery case, battery posts, and cables for damage.

3. Check the electrolyte level. See page 4005-4.

4. If you added water to the battery, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte.

790863A

Specific Gravity Check A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of the level of charge for each cell.

1. Temperature in ° F 2. Temperature in ° C Specific Gravity Chart

Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7°C.

4. Make a record of the corrected specific gravity reading for each cell.

When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not have a ther mometer, get a ther mometer to check the temperature of the electrolyte. The thermometer must indicate a high temperature of at least 52°C.

5. If the difference between the high reading and the low reading is .050 or more, charge the battery and check the specific gravity again. If after charging, the difference is still .050 or more, install a new battery.

1. Remove enough electrolyte from a cell so that the float is free in the tube.

NOTE: If the specific gravity cannot be checked without first adding water to the cell, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte. Then check the specific gravity.

6. The corrected specific gravity reading shows the level of charge for the cell. The level of charge must be at least 75% in each of the cells. In maintenance free batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.240 or higher. In all other batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.230 or higher.

2. Read the float.

7. If the difference between the high reading and the low reading is less then .050, and the level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.

3. Read the thermometer. If the reading is above 26.7° C add specific gravity points to the reading for specific gravity. If the reading is below 26.7° C subtract specific gravity points from the reading for specific gravity. See the following illustration and add or subtract specific gravity points as needed.

8. If the difference between the high reading and the low reading is less than .050, but the level of charge is less than 75% in any of the cells, charge the battery and check the specific gravity again. If after charging: A. The level of charge is less than 75% in any of the cells, discard the battery.

B. The level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.

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Capacity (Load) Test This test can be done using a variable load tester. Connect the test equipment according to the instructions of the manufacturer of the equipment.

1. The level of charge of the battery must be at least 75%.

Do the Specific Gravity Check in this section.

2. Prepare the tester for the test.

NOTE: Never apply a load for longer than 15 seconds.

After each 15 seconds, turn the load control knob to OFF for at least one minute.

4. Apply a 15 ampere load to the battery for 15 seconds.

Wait at least three minutes before continuing with the test.

5. Check and make a record of the temperature of the electrolyte.

A. Select the voltmeter range that will measure 1 to 18 volts.

6. Find the correct load for this test in Specifications in Section 4002.

B. Make sure the load control knob is in the OFF position.

NOTE: The correct load is half of the cold cranking amperes at -17°C.

C. Select the ammeter range that will measure 0 to 1000 amperes.

7. Turn the load control knob until the ammeter indicates the specified load. Keep the load for 15 seconds and read the voltmeter. Turn the load control knob to OFF.

D. Move the volt lead switch to the INT. position.

8. Compare the test reading and the temperature of the electrolyte to the chart below.

3. Connect the tester to the battery as shown.

1

2

Temperature of electrolyte

Minimum Voltage

21° C and above ............................................................

16° C .............................................................................

10° C .............................................................................

4° C ...............................................................................

-1° C ..............................................................................

-7° C ..............................................................................

-12° C ............................................................................

-18° C .............................................................................

9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

A. If the test result is equal to or more than the voltage shown, the battery is in good condition.

B. If the test result is less than the voltage shown, discard the battery.

790499

1. Load Control Knob

2. Ammeter Clamp

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4005-8

CHARGING A BATTERY The charging rate must be decreased if:

!

WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83A

Before you charge the battery, check the level of the electrolyte.

It is difficult to give an exact charging rate because of the following var iable conditions: (1) temperature of the electrolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and time.

1. Too much gas causes the electrolyte to flow from the cells.

2. The temperature of the electrolyte rises above 52°C. NOTE: For the best charge, use the slow charging rates.

The battery is fully charged when, over a three hour period at a low charging rate, no cell is giving too much gas, and the specific gravity does not change.

See Specifications in Section 4002 for the reserve capacity of the battery in this machine.

CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES Recommended Rate * and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications 80 Minutes or Less

Above 80 to 125 Minutes

Above 125 to 170 Minutes

Above 170 to 250 Minutes

Slow Charge

Fast Charge

10 Hours at 5 Amperes

2.5 Hours at 20 Amperes

5 Hours at 10 Amperes

1.5 Hours at 30 Amperes

15 Hours at 5 Amperes

3.75 Hours at 20 Amperes

7.5 Hours at 10 Amperes

1.5 Hours at 50 Amperes

20 Hours at 5 Amperes

5 Hours at 20 Amperes

10 Hours at 10 Amperes

2 Hours of 50 Amperes

30 Hours at 5 Amperes

7.5 Hours at 20 Amperes

15 Hours at 10 Amperes

3 Hours at 50 Amperes

* Initial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery.

If the center part of the decal has been removed to get

access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal.

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CHARGING GUIDE FOR BATTERIES OTHER THAN MAINTENANCE FREE BATTIERES Recommended Rate * and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications 80 Minutes or Less

Above 80 to 125 Minutes

Above 125 to 170 Minutes

Above 170 to 250 Minutes

Above 250 Minutes

Slow Charge

Fast Charge

10 Hours at 5 Amperes

2.5 Hours at 20 Amperes

5 Hours at 10 Amperes

1.5 Hours at 30 Amperes

15 Hours at 5 Amperes

3.75 Hours at 20 Amperes

7.5 Hours at 10 Amperes

1.5 Hours at 50 Amperes

20 Hours at 5 Amperes

5 Hours at 20 Amperes

10 Hours at 10 Amperes

2 Hours of 50 Amperes

30 Hours at 5 Amperes

7.5 Hours at 20 Amperes

15 Hours at 10 Amperes

3 Hours at 50 Amperes

24 Hours at 10 Amperes

6 Hours at 40 Amperes 4 Hours at 60 Amperes

* Initial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE 1. Remove the caps from the battery.

4. Connect a battery charger to the battery.

2. Fill each cell to the top of the separators with electrolyte.

This will permit the volume of electrolyte to increase when heated by charging the battery.

5. Charge the battery at 30 amperes until the specific gravity is 1.250 or more and the temperature of the electrolyte is at least 15.5°C.

3. Install the caps on the battery. If the battery in your machine must have nonspill caps, install the nonspill caps. See Specifications in Section 4002 to find if the battery in your machine must have nonspill caps.

6. If necessary, fill each cell with electrolyte until the electrolyte is just below split ring at the bottom of the cell opening.

7

SECTION INDEX - POWER TRAIN Section Title Section Number Removal and Installation of Power Train Components .................................................................................................... 6000 Hydrostatic System Troubleshooting............................................................................................................................ 6002 Pressure Reducing Valve and Sequence Valve........................................................................................................................... 6003 Piston Pumps .......................................................................................................................................................... 6004 Drive Motors ........................................................................................................................................................... 6005 Sprockets, Chains, and Axle Housings ...................................................................................................................................... 6007 Brake Valve................................................................................................................................................................................ 6008 Wheels and Tires ...................................................................................................................................................................... 6011

7

Section 6000

6000

REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

6000-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 HYDROSTATIC START-UP PROCEDURE ...................................................................................................................... 3 TANDEM PISTON PUMPS ............................................................................................................................................

Removal .................................................................................................................................................................

Installation ..............................................................................................................................................................

Charge Oil, Case Drain, and Gear Pump Connections ...................................................................................................

Hydrostatic Motor Connections ...................................................................................................................................

4 4 5 6 7

HYDROSTATIC MOTORS ............................................................................................................................................ 8 Removal ................................................................................................................................................................. 8 Installation .............................................................................................................................................................. 9

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SPECIFICATIONS Weights (approximate) Tandem Piston Pumps with Gear Pump .............................................................................................................................. 60 kg Hydrostatic Motor ................................................................................................................................................................. 19 kg Special Torques Cap Screws for Drive Coupling ................................................................................................................................. 41 to 51 Nm Cap Screws for Piston Pumps ................................................................................................................................... 68 to 81 Nm Allen Head Screws for Gear Pump ............................................................................................................................. 48 to 57 Nm Wheel Nuts ............................................................................................................................................................... 81 to 95 Nm

IMPORTANT: There is no charge pump on this machine. Charge oil for the closed loop hydrostatic system is supplied by return oil from the gear pump hydraulic system. DO NOT run the engine if the return oil from the gear pump hydraulic system is not providing adequate charge oil flow. DO NOT make any test connections or flowmeter connections which will prevent the flow of this return oil/charge oil.

HYDROSTATIC START-UP PROCEDURE Do this procedure any time the hydraulic oil has been removed from the piston pumps.

6. Connect a pressure gauge with a capacity of at least 28 bar to the test port.

1. If necessary, fill the reservoir to the correct level. See Section 1002 for the correct hydraulic oil.

7. Start and run the engine at low idle. Observe the indication on the pressure gauge to make sure the piston pumps have charge pressure. Operate at low idle for a few minutes to allow the air to escape from the closed loop system.

2. Change the hydraulic filter.

3. Remove the socket head plug from the top of each piston pump housing. This will allow the air to bleed out as the piston pump fills with hydraulic oil.

4. When the oil level in each piston pump is at the bottom of the hole for the socket head plug, install the socket head plugs.

5. Find the elbow connected to the outlet port of the hydraulic filter. Remove the 1/8 inch NPT pipe plug from the test port in the elbow.

8. Run the engine at full throttle. Read the pressure gauge and record the charge pressure indication. Stop the engine.

9. The pressure indication must be at least 9.0 bar at full throttle. If the pressure indication is not correct, see Section 6002 for testing and adjusting the charge pressure.

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6000-4

TANDEM PISTON PUMPS Removal 1. Tilt the ROPS canopy forward according to the instructions in Section 9003.

2. Clean the hydraulic pump and the area around the hydraulic pump.

3. Fasten identification tags to the hoses which will be removed so that you can connect the hoses correctly during installation.

4. Remove the cap from the hydraulic reservoir.

5. Connect a vacuum pump to the hydraulic reservoir.

12. Remove the two Allen head screws that fasten the gear pump to the piston pump.

13. Remove the gear pump. The coupling for the gear pump may stay with the gear pump or with the front piston pump.

NOTE: There are no seals between the front piston pump and the gear pump. Oil can flow from the front piston pump when the gear pump is removed.

14. Fasten acceptable lifting equipment to the piston pumps.

15. Remove the two cap screws and lock washers which fasten the piston pumps to the flywheel housing.

6. Start the vacuum pump.

16. Separate the piston pumps from the flywheel housing and the drive coupling.

7. Disconnect the hoses to the inlet and the outlet of the gear pump. Install plugs in the hoses and caps on the fittings.

17. Remove the piston pumps from the machine.

8. Disconnect the hoses at the work ports on top of the piston pumps. Install plugs in the hoses and caps on the fittings.

9. Disconnect the case drain hoses and the charge oil hose from the bottom of the piston pumps. Install plugs in the hoses and caps on the fittings.

10. Make sure that all the plugs in the hoses are tight. Stop the vacuum pump.

11. Remove the self-locking nuts, flat washers, and bolts which fasten the transmission control rods to the control arms on the piston pumps.

18. If the splines on the shaft for the piston pumps are damaged, do the following procedure: A. Remove the hardware that fastens the flywheel housing to the engine. Make a record of the locations of the bolts that hold the ground cable and the wiring harnesses so that these parts can be installed correctly later.

B. Remove the flywheel housing.

C. Remove the cap screws and lock washers that fasten the drive coupling to the engine. Remove the drive coupling. Inspect the drive coupling for damage. Repair or replace the drive coupling if necessary.

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Installation IMPORTANT: If the tandem pump was removed for repair of the piston pumps, or if new piston pumps are being installed because of a failure, you must learn the cause and the results of the failure. If the failure caused broken par ts to be sent to the motors, the motors must b e r e m o ve d a n d d i s a s s e m b l e d fo r i n s p e c t i o n a n d c l e a n i n g . T h e n c l e a n t h e c o m p l e t e hy d r a u l i c a n d hy d r o s t a t i c s y s t e m a c c o r d i n g t o t h e i n s t r u c t i o n s i n Section 8003.

1. If the drive coupling was removed, do the following procedure: A. Apply 271 (red) Loctite to the threads of the cap screws for the drive coupling. Put the drive coupling into position and install the cap screws and the lock washers. Tighten the cap screws to a torque of 41 to 51 Nm. B. Put the flywheel housing into position and install the hardware. Make sure that the hardware holds the ground cable and the wiring harnesses in the correct positions.

2. Use acceptable lifting equipment to put the piston pumps into position.

3. Apply MOLYKOTE Type G lubricant to the splines on the shaft for the piston pumps. Use the instructions on the container.

4. Move the piston pump into position in the drive coupling and the flywheel housing.

5. Apply Loctite 242 to the threads on the two cap screws that fasten the piston pumps to the flywheel housing.

Install and tighten the cap screws and lock washers to a torque of 68 to 81 Nm. 6. Make sure that the coupling for the gear pump is installed between the gear pump and the piston pump. Put the gear pump into position on the piston pump.

7. Install the two Allen head screws to fasten the gear pump to the piston pump. Tighten the Allen head screws to a torque of 48 to 57 Nm. 8. Install the bolts, flat washers, and self-locking nuts which fasten the transmission control rods to the control arms on the piston pumps.

9. Start the vacuum pump.

10. Remove the plugs from the hoses and the caps from the fittings.

11. Connect the hoses to the piston pumps and to the gear pump.

12. Stop the vacuum pump. Remove the vacuum pump from the hydraulic reservoir. Install the cap on the hydraulic reservoir.

13. Fasten the ROPS canopy in the operating position according to the instructions in Section 9003.

14. Do the Hydrostatic Start-Up Procedure on page 3 of this section.

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6000-6

2

1

8

7

5 6

9

bt96f190

3

4 4

BT96F190

1. Hydraulic Filter 2. From Oil Cooler 3. Charge Oil Hose

4. Case Drain Hose 5. To Hydraulic Reservoir 6. Tandem Piston Pumps

7. Gear Pump 8. To Loader Control Valve 9. From Hydraulic Reservoir

Charge Oil, Case Drain, and Gear Pump Connections

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3

4 2

7

1

5

6 BT96F191

1. Tandem Piston Pumps 2. Gear Pump 3. LH Hydrostatic Motor

4. From Brake Valve 5. Drain Manifold 6. RH Hydrostatic Motor

7. Case Drain Hose

Hydrostatic Motor Connections

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6000-8

HYDROSTATIC MOTORS Removal 1. Tilt the ROPS canopy forward according to the instructions in Section 9003.

2. Clean the hydrostatic motor and the area around the hydrostatic motor.

3. Raise the wheels off the floor and use blocks to hold the machine in place.

4. Remove the wheel nuts and the wheels.

5. Remove the nuts, the lock washers, and the flat washers that hold the cover for the motor sprocket.

6. Remove the cover.

7. If the gasket is damaged, remove the gasket from the cover (or the frame).

8. The thrust washers can stay with the motor shaft or the cover. If there are thrust washers on the motor shaft, remove the thrust washers.

9. Fasten identification tags to the hoses which are connected to the motor so that you can connect the hoses correctly during installation.

10. Remove the cap from the hydraulic reservoir.

11. Connect a vacuum pump to the hydraulic reservoir.

12. Start the vacuum pump.

13. Disconnect the hoses from the hydrostatic motor.

14. Install plugs in the hoses and caps on the fittings.

15. Make sure that all the plugs in the hoses are tight. Stop the vacuum pump.

16. Fasten acceptable lifting equipment to the hydrostatic motor.

17. Remove the nuts, lock washers, and bolts which fasten the hydrostatic motor to the machine.

18. Disengage the hydrostatic motor from the motor sprocket and the frame of the machine. Remove the hydrostatic motor.

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A t+ to disp ay temp ate i ormatio 6000-9

Installation IMPORTANT: If the hydrostatic motor was removed for repair, or if a new hydrostatic motor is being installed because of a failure, you must learn the cause and the results of the failure. If the failure caused broken parts to be sent to the piston pumps, the piston pumps must be removed and disassembled for inspection and cleaning.

T h e n c l e a n t h e c o m p l e t e hy d ra u l i c a n d hy d r o s t a t i c system according to the instructions in Section 8003.

1. Apply MOLYKOTE Type G lubricant to the splines on the motor shaft. Use the instructions on the container.

2. Apply a 3 mm bead of form-in-place gasket material around the pilot of the hydrostatic motor.

3. Make sure that the motor sprocket is in position in the chains. Hold the motor sprocket in position as you install the hydrostatic motor in the frame of the machine. Make sure that the splines on the motor shaft engage the splines in the motor sprocket.

4. Install the bolts, lock washers, and nuts to fasten the hydrostatic motor to the frame. Tighten the nuts to 95 to 122 Nm. 5. Start the vacuum pump.

6. Remove the plugs from the hoses and the caps from the fittings.

7. Connect the hoses to the hydrostatic motor.

8. Stop the vacuum pump. Remove the vacuum pump from the hydraulic reservoir. Install the cap on the hydraulic reservoir.

9. If necessary, adjust the deflection of the chains according to the instructions in Section 6007.

10. Install the thrust washers on the motor shaft.

11. If necessary, install a new gasket for the cover for the motor sprocket.

12. Install the cover, the flat washers, the lock washers, and the nuts. The cover can be difficult to install because of the self-aligning bushing that holds the needle bearing.

DO NOT use force to install the cover.

13. Install the wheels and the wheel nuts. DO NOT use an impact wrench to install the wheel nuts. Tighten the wheel nuts to a torque of 108 to 122 Nm. 14. Fasten the ROPS canopy in the operating position according to the instructions in Section 9003.

15. Start the engine and run the engine at low idle.

16. Slowly move the left hand control lever all the way forward and all the way rearward until the left hand drive system works correctly.

17. Slowly move the right hand control lever all the way forward and all the way rearward until the right hand drive system works correctly.

18. Remove the blocks and lower the wheels to the floor.

7

6002 HYDROSTATIC SYSTEM TROUBLESHOOTING

6002

Section

6002-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 SPECIAL TOOLS ........................................................................................................................................................ 3 TROUBLESHOOTING PROCEDURES ...........................................................................................................................

Only One Transmission (Right or Left) Works Correctly ..................................................................................................

Machine Does Not Have Enough Tractive Effort (Neither Transmission Works Correctly) ....................................................

Parking Brake in Drive Motor Does Not Release ...........................................................................................................

Parking Brake in Drive Motor Does Not Engage or Does Not Hold the Machine When Engaged ...........................................

4 4 5 6 6

CHARGE PRESSURE TEST ......................................................................................................................................... 7 CIRCUIT RELIEF PRESSURE TEST .............................................................................................................................. 8 LEAKAGE TEST FOR DRIVE MOTORS .......................................................................................................................... 9 REDUCING VALVE ................................................................................................................................................... 10 Pressure Check ..................................................................................................................................................... 10 Adjustment ........................................................................................................................................................... 10 BRAKE CONTROL VALVE .......................................................................................................................................... 11 TANDEM PISTON PUMPS WITH GEAR PUMP .............................................................................................................. 12 DRIVE MOTORS ....................................................................................................................................................... 13

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-3

SPECIFICATIONS Charge pressure (minimum) .............................................................................................................................. 9.0 bar at full throttle Circuit relief pressure ...................................................................................................................................................203 to 217 bar Pressure reducing valve for brakes .............................................................................................................................26.9 to 29.0 bar Sequence Valve (See Section 8002 for adjustment procedure) ...................................................................................29.3 to 32.8 bar IMPORTANT: There is no charge pump on this machine. Charge oil for the closed loop hydrostatic system is supplied by return oil from the gear pump hydraulic system. DO NOT run the engine if the return oil from the gear pump hydraulic system is not providing adequate charge oil flow. DO NOT make any test connections or flowmeter connections which will prevent the flow of this return oil/charge oil.

SPECIAL TOOLS

B877910

B009638M

Pressure Test Fitting Kit

Vacuum Pump

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6002-4

TROUBLESHOOTING PROCEDURES Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts.

Check the oil level in the hydraulic reservoir. Is the oil level correct?

NO

Fill the hydraulic reservoir with the oil specified in Section 1002.

NO

See Section 6007 and check the drive chain tension.

Adjust as necessary. Is there still a problem?

YES

See Section 9000 and check the control linkages. Check the operation of the machine again. Does the machine operate correctly?

YES

NO Troubleshooting is complete.

YES Troubleshooting is complete.

Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which transmission (right or left) has problems.

Only One Transmission (Right or Left) Works Correctly Check to see that the stops for the direction control levers are adjusted correctly. See Section 9000. Is there still a problem?

NO

Troubleshooting is complete.

YES

See page 8 and check the pressure setting of the circuit relief valve for the transmission which has the problem.

Adjust as necessary. Is there still a problem?

NO

Troubleshooting is complete.

YES See page 9 and check for leakage in the drive motor.

Repair or replace the piston pump or the drive motor as necessary.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-5

Machine Does Not Have Enough Tractive Effort (Neither Transmission Works Correctly) See Section 8002 and check the pressure setting of the sequence valve. Is the pressure setting correct?

NO

Adjust the sequence valve.

YES

See Section 3002 and check the full throttle engine speed. Adjust as necessary. Is there still a problem?

NO

Troubleshooting is complete.

YES

Do the loader circuits (lift and bucket) have acceptable power?

NO

YES

Replace the hydraulic filter. Is there still a problem?

There can be a problem in the engine or the fuel system.

Repair as necessary.

NOTE: If power in the loader circuits is very low, there can be a problem in the gear pump. See Section 8002 and do the Pump Output Test.

Troubleshooting is complete.

NO

YES See page 7 and check the charge pressure. Adjust as necessary. Is there still a problem?

Troubleshooting is complete.

NO

YES See page 9 and check for leakage in the drive motors.

Repair or replace the piston pumps or the drive motors as necessary.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6002-6

Parking Brake in Drive Motor Does Not Release See Section 9000 and check the seat bar limit switch and the parking brake switch. Is the operation correct?

NO

Repair or replace these parts as necessary.

YES Is there a problem in both drive motors?

NO

See Section 6005. Repair or replace the drive motor which has the bad parking brake.

YES See Section 8002 and check the pressure setting of the sequence valve. Is the pressure setting correct?

NO

Adjust the sequence valve.

YES See page 10 and check the pressure setting of the reducing valve. Is the pressure setting correct?

NO

Adjust the reducing valve.

YES

See page 11 and check the operation of the brake control valve. Does the brake control valve operate correctly?

NO

Repair or replace the brake control valve.

YES See Section 6005. Repair or replace the parking brakes in both drive motors.

Parking Brake in Drive Motor Does Not Engage or Does Not Hold the Machine When Engaged See Section 9000 and check the seat bar limit switch and the parking brake switch. Is the operation correct?

NO

Repair or replace these parts as necessary.

YES

See page 11 and check the operation of the brake control valve. Does the brake control valve operate correctly?

NO

Repair or replace the brake control valve.

YES

See Section 6005. Repair or replace the parking brake in the drive motor.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-7

CHARGE PRESSURE TEST IMPORTANT: There is no charge pump in the piston pumps. DO NOT run the engine if the return oil from the gear pump hydraulic system is not providing adequate charge oil flow.

1. Find the elbow connected to the outlet port of the hydraulic filter. Remove the 1/8 inch NPT pipe plug from the test port in the elbow.

2. Connect a pressure gauge with a capacity of at least 28 bar to the test port.

3. Run the engine at full throttle. Read the pressure gauge and record the charge pressure indication. Stop the engine.

4. The charge pressure must be 9.0 bar minimum at full throttle. If the charge pressure is correct, go to step 7. If the charge pressure is low, do steps 5 and 6 as necessary.

5. If the charge pressure is low, remove and inspect the parts of the charge relief valve. Repair or replace the charge relief valve as necessary. You can connect the vacuum pump to the hydraulic reservoir to hold the hydraulic oil when the charge relief valve is removed.

6. If the parts of the charge relief valve are good, add shims from the shim kit to adjust the charge pressure. A shim with a thickness of 0.25 mm will increase the charge pressure 0.5 bar. Continue to adjust the charge relief valve and to check the charge pressure until the charge pressure is as specified in step 4. Then go to step 7.

7. Raise the machine until the tires are off the floor. Use acceptable supports to hold the machine off the floor.

8. Start the engine and run the engine at low idle. Raise the seat bars and pull up the knob on the parking brake switch (Engaged position).

9. Run the engine at full throttle. Slowly push the direction control levers forward just enough to load the hydrostatic system against the parking brake without decreasing the engine speed. Read the pressure gauge. The pressure must be within 2.1 bar of the pressure in step 3 (or the pressure in step 6, if you did step 6).

10. Run the engine at full throttle. Slowly push the direction c o n t r o l l eve r s r e a r wa r d j u s t e n o u g h t o l o a d t h e hydrostatic system against the parking brake without decreasing the engine speed. Read the pressure gauge.

The pressure must be within 2.1 bar of the pressure in step 3 (or the pressure in step 6, if you did step 6).

11. If the pressure is not correct in step 9 or step 10, there is too much leakage in the hydrostatic system. See page 9 and do the leakage test for the drive motors to determine which components need repair.

1 1. Toward Engine

2 940L93

2. Charge Relief Valve

Bottom View of Piston Pumps

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6002-8

CIRCUIT RELIEF PRESSURE TEST 1. Raise the machine until the tires are off the floor. Use acceptable supports to hold the machine off the floor.

5. Decrease the engine speed to low idle and stop the engine.

2. See the illustration on page 12 (not the illustrations on this page) for the locations of the ports in steps A and B, below:

6. See Specifications on page 3 for the correct pressure. If the pressure is not correct, use a new circuit relief valve.

See the illustrations on this page for the correct locations of the circuit relief valves. You can temporarily repair a forward circuit by interchanging the reverse circuit relief valve with the forward circuit relief valve.

A. If you are testing the circuit relief valves for the left motor circuits, disconnect the hoses from the elbows at the LEFT MOTOR FORWARD port and the LEFT MOTOR REVERSE port (the ports closest to the rear of the machine). The elbows are 1-1/16 12 JIC. Install a reducer and a 414 bar pressure gauge on the elbow for the circuit to be tested.

Install a steel cap on the other elbow.

1

B. If you are testing the circuit relief valves for the right motor circuits, disconnect the hoses from the elbows at the RIGHT MOTOR REVERSE port and the RIGHT MOTOR FORWARD por t (the por ts closest to the front of the machine). The elbows are 1-1/16 - 12 JIC. Install a reducer and a 414 bar pressure gauge on the elbow for the circuit to be tested. Install a steel cap on the other elbow.

2

4

942L93

Right Side View

3. The oil must be at operating temperature. To heat the oil, do the following steps:

1

A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

4. Run the engine at full throttle. Move the direction control lever for the circuit being tested approximately half stroke while you watch the pressure gauge. Continue to move the direction control lever until the pressure stops increasing. Record the pressure. Repeat this procedure several times to be sure of the reading.

5

3

Left Side View 1.

2.

3.

4.

5.

Toward Engine Circuit Relief Valve - Left Motor Forward Circuit Relief Valve - Left Motor Reverse Circuit Relief Valve - Right Motor Reverse Circuit Relief Valve - Right Motor Forward

FOR EUROPEAN MACHINES ONLY

943L93

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-9

LEAKAGE TEST FOR DRIVE MOTORS 1. Raise the machine until the tires are off the floor. Use acceptable supports to hold the machine off the floor.

2. The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

5. Find the case drain hose for the drive motor to be tested.

Follow the case drain hose to the fitting which connects it to the drain manifold. Disconnect the case drain hose from the fitting. Install a cap on the fitting.

6. Connect the case drain hose to another hose which is long enough to reach outside the machine. Fasten the end of this hose in a 19 litre container.

7. Start the engine and run the engine at full throttle.

B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

3. Run the engine at low idle. Raise the seat bars and pull up the knob on the parking brake switch (Engaged position).

4. See the illustration on page 12. If you are testing the left drive motor, find the hose connected to the LEFT MOTOR FORWARD port of the piston pumps. If you are testing the right drive motor, find the hose connected to the RIGHT MOTOR FORWARD port of the piston pumps.

Follow this hose to the drive motor to find the FORWARD port of the drive motor. Disconnect the hose from the drive motor. Install a tee (7/8 - 14 JIC) in the FORWARD port of the drive motor. Connect the hose to the tee.

Connect a 345 bar pressure gauge to the other leg of the tee.

8. Slowly move the control lever forward until the pressure gauge indicates 138 bar. Hold the control lever in position for 30 seconds.

9. Decrease the engine speed to low idle and stop the engine.

10. Measure the amount of hydraulic oil in the container.

11. If the amount was more than 7.5 litres, there is a leakage problem in the motor. Repair or replace as necessary.

12. If the amount was less than 7.5 litres, any leakage problem in the system is probably in the piston pump.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6002-10

REDUCING VALVE Pressure Check

5. Compare the reading with the specification on page 3. If the reading is not correct, adjust the reducing valve.

1. Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

Adjustment

2. The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

See the illustration. The reducing valve is below the floor plate. Remove the cap for access to the adjusting screw. After you adjust the reducing valve, do the pressure check again to make sure that the setting is correct.

1 B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

5

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

2

3. See the illustration. The reducing valve is below the floor plate. Use a pressure gauge with a capacity of at least 41 bar. Find the hose which is routed between the reducing valve and the brake control valve. Disconnect the hose from the reducing valve. Install a plug in the hose.

Connect the pressure gauge to the reducing valve.

4. Run the engine at full throttle. Make sure that all control levers are in the NEUTRAL position. Leave the control levers in the NEUTRAL position while you read the pressure gauge. Then decrease the engine speed to low idle. Stop the engine.

3 4 BT96B112

1.

2.

3.

4.

5.

Sequence Valve Reducing Valve To Brake Control Valve Connect Pressure Gauge Here Cap and Adjusting Screw

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-11

BRAKE CONTROL VALVE 1. Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

2. The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

4. Run the engine at low idle. Lower the seat bars and push down the knob on the parking brake switch (Released position). Read the pressure gauge. The pressure indication must be 26.9 to 29.0 bar.

5. Continue to run the engine at low idle. Raise the seat bars and pull up the knob on the parking brake switch (Engaged position). Read the pressure gauge. The pressure indication must be much lower than 26.9 bar.

The pressure indication will probably be below 10.3 bar.

6. If the pressure indications in step 4 and step 5 were not correct, repair or replace the brake control valve.

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

3. See the illustration. The brake control valve is fastened to a bracket above and to the left of the hydraulic pump. Use a pressure gauge with a capacity of at least 600 psi (41 bar). Disconnect one of the brake hoses from the tee in the top of the brake control valve. Install a plug in the brake hose. Connect the pressure gauge to the tee.

4

bt96c027

3

2

6 5

1 BT96C027

1.

2.

3.

4.

5.

6.

Brake Control Valve Brake Hose To Right Drive Motor Brake Hose To Left Drive Motor Tee. Connect Pressure Gauge Here From Reducing Valve To Drain Manifold

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6002-12

TANDEM PISTON PUMPS WITH GEAR PUMP 6

1

6 14

12

7

7

2

7

7

13

11 6

8

4

9

10

1

12

1052L93C

6

14 1

2

3 926L93

13

11

5

TOP VIEW 1.

2.

3.

4.

5.

6.

7.

Piston Pump Gear Pump Toward Engine Left Hand Drive Control Right Hand Drive Control Circuit Relief Valve Charge Circuit Check Valve

8.

9.

10.

11.

12.

13.

14.

Charge Pressure Relief Valve Charge Oil Inlet Case Drain Port Left Motor Forward Port Left Motor Reverse Port Right Motor Reverse Port Right Motor Forward Port

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6002-13

DRIVE MOTORS

2 1.

2.

3.

4.

5.

6.

7.

8.

1

4

Inlet/Outlet Motor Spool Case Drain Brake Brake Springs Brake Release Pressure Brake Drain

5 3 1

1

6 7

8

2

7

5

8

6

3

4

7

1

BT96B113

FOR EUROPEAN MACHINES ONLY

7

6003 PRESSURE REDUCING VALVE AND SEQUENCE VALVE

6003

Section

6003-2

TABLE OF CONTENTS PRESSURE REDUCING VALVE .................................................................................................................................... 3 Disassembly ........................................................................................................................................................... 3 Assembly ................................................................................................................................................................ 3 SEQUENCE VALVE ..................................................................................................................................................... 4 Disassembly ........................................................................................................................................................... 4 Assembly ................................................................................................................................................................ 4

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6003-3

PRESSURE REDUCING VALVE Assembly

Disassembly 1. Fasten the pressure reducing valve in the vise with soft jaws.

1. Install new O-rings (2) and backup rings (3) on the cartridge (4) as shown in the photo.

2. Loosen and remove the cartridge (4) assembly from the body (1).

2. Lubricate the O-rings (2) and backup rings (3) with clean oil.

3. Remove and Discard the O-rings (2) and backup rings (3) from the cartridge (4).

3. Install the cartridge (4) assembly in the body (1).

3 2

4

2

3

4

3 BP96E008

3 1

2

BS96D258

1. Body 2. Backup Ring

3. O-Ring 4. Cartridge

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6003-4

SEQUENCE VALVE Assembly

Disassembly 1. Fasten the sequence valve in the vise with soft jaws.

1. Install new O-rings (2) and backup rings (3) on the cartridge (1) as shown in the photo.

2. Loosen and remove the cartridge (1) assembly from the body (4).

3. Remove and Discard the O-rings (2) and backup rings (3) from the cartridge (1).

2. Lubricate the O-rings (2) and backup rings (3) with clean oil.

3. Install the cartridge (1) assembly in the body (4).

2 3

2

1

1 3 2

3

BP96E009

2 2 4

3 3 BS96D259

1. Cartridge 2. O-Ring

3. Backup Ring 4. Body

FOR EUROPEAN MACHINES ONLY

Section

PISTON PUMPS

6004

6004

6004-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 2 SPECIAL TORQUES .................................................................................................................................................... 2 TANDEM PUMPS ........................................................................................................................................................ 3 LEFT HAND DRIVE PUMP ............................................................................................................................................

Disassembly ...........................................................................................................................................................

Inspection ...............................................................................................................................................................

Assembly ................................................................................................................................................................

RIGHT HAND DRIVE PUMP .......................................................................................................................................

Disassembly .........................................................................................................................................................

Inspection .............................................................................................................................................................

Assembly ..............................................................................................................................................................

4 4 8 9

14 14 18 19

SPECIFICATIONS Charge Relief Pressure (See Section 6002 for adjustment procedure.) ............................................ Minimum 9.0 bar at Full Throttle Circuit Relief Pressures (See Section 6002 for test procedure.) ................................................................................... 200 to 214 bar Swash Plate Bearing Preload.................................................................................................................................... 0.05 to 0.10 mm

SPECIAL TORQUES Circuit Relief Valves .........................................................................................................................................................40 to 65 Nm Charge Relief Valve .......................................................................................................................................................55 to 135 Nm End Cap to Piston Pump ..................................................................................................................................................45 to 60 Nm Piston Pump to Piston Pump............................................................................................................................................45 to 60 Nm Trunnion Cap ...................................................................................................................................................................24 to 30 Nm

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-3

TANDEM PUMPS 1

3 6

8

5

7

4

2 926L93

1.

2.

3.

4.

Left Hand Drive Control Right Hand Drive Control Gear Pump Toward Engine

5.

6.

7.

8.

STEP 1

Left Motor Forward Left Motor Reverse Right Motor Forward Right Motor Reverse

STEP 2

A23307 Remove the gear pump and the drive coupling. See Section 8004 for the gear pump repair.

A23308 Separate the piston pumps between the end caps. Remove the drive coupling and discard the O-rings.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-4

LEFT HAND DRIVE PUMP Disassembly

STEP 6

STEP 3

A23044 A23310

Remove the charge relief plug, shims, spring and poppet.

Discard the O-ring.

Remove the end cap. Discard the gasket.

STEP 7 STEP 4

A23046 A23042

Remove needle bearing.

Remove the valve plate.

STEP 8 STEP 5

A23028 A23043 Remove the plug, spring and circuit relief valve from both sides of the end cap. Discard the O-rings.

Remove the cylinder and piston assembly.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-5

STEP 9

STEP 12

A23029

A21068

Remove the thrust plate.

Install a bolt with two washers to compress the spring.

STEP 10

STEP 13

A21076 Remove the pistons and slipper guide.

A21067 Remove the retaining ring. Release the spring and remove the spring seats and spring.

STEP 11 STEP 14

A21609 A18548

Remove the retainer guide, washer, pins and pin retainer.

Remove the snap ring.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-6

STEP 15

STEP 18

A18549

A22853

Remove the seal and retainer.

Remove the snap ring and bearing from the drive shaft.

STEP 16

STEP 19

A18550 Remove and discard the O-ring and seal from the retainer.

STEP 17

A18587 Remove the blank trunnion cap, the quad ring, the spacer, the shim or shims, and the bearing cup and cone. Record the locations of all items. Record the shim size and quantity.

STEP 20

A18582 Remove the drive shaft and bearing.

A18585 Remove the trunnion cap, the quad ring, the spacer, and shims from the other side. Record the locations of all items.

Record the shim size and quantity. Remove the seal from the trunnion cap.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-7

STEP 21

STEP 22

A23035

A23036

Remove the bearing cup.

Remove the swash plate. Remove the bearing cone.

2

4

3

10 8 9

5 3

6 7

1 4 3

2 269L94

1.

2.

3.

4.

Coupling Plug Spring Circuit Relief Valve

5. Poppet 6. Shim 7. Charge Relief Valve

8. Needle Bearing 9. Gasket 10. Top Side When Installed in Machine

ILLUSTRATION OF END CAP FOR LEFT HAND DRIVE PUMP

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-8

Inspection 1. Wash all parts in cleaning solvent. Use a lint free cloth, or air dry the parts. Be careful of the machined surfaces on the parts.

NOTE: The parts must be as clean as possible for assembly.

2. Replace all O-rings, seals, and gaskets. Lightly lubricate all O-rings with petroleum jelly prior to assembly. All gasket sealing surfaces must be clean before installing a new gasket.

3. Inspect the splines on the input shaft and coupling. If the splines are worn or damaged, use new parts as required.

4. Inspect both sides of the thrust plate and valve plate. If the surfaces have pitting or scoring, use new parts. Make sure that the thrust plate and valve plate are flat.

5. Inspect the area of the cylinder block that touches the valve plate. This area must be smooth and have no grooves or metal deposits.

6. Check to make sure that the pistons move freely in the cylinder block. Check for scoring and wear in the cylinder block.

7. Inspect the outer surface of the pistons. The piston shoes must be flat, smooth, and free of metal deposits. Do not try to repair the pistons or piston shoes. If there is any damage, replace the pistons.

8. Inspect the slipper guide and the thrust washer. The slipper guide must be flat and have no wear or cracks.

9. Check the cylinder block. If the spring is broken, make sure that there is no damage to the inside of the cylinder block.

10. Check the spring pin in the end cap. If the spring pin is damaged, or loose, it must be replaced.

11. Inspect the swash plate bearings and the bearing cups for flat areas, pitting, scoring, and other damage. Always install a new roller bearing and bearing cup at the same time.

12. Inspect the roller bearing in the pump housing and the needle bear ing in the pump end cap. Replace as necessary.

13. Inspect the parts of the charge relief valve and the check valves. Use new parts as required.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-9

1

2

3

3 8

4 5

9

6 6 7 16 6

5 4 2

1

15 14 13 12

10

11 270L94

1.

2.

3.

4.

Trunnion Cap Quad Ring Seal Spacer

5.

6.

7.

8.

Shims Bearing Drive Shaft O-Ring

9. Seal Carrier 10. Valve Plate 11. Cylinder Block 12. Slipper Guide

Assembly

13. Pistons 14. Thrust Plate 15. Swash Plate 16. Bottom Side of Pump When Installed in Machine

STEP 24

STEP 23

A23037 A23039 Install a new seal in trunnion cap. Seal lip goes to inside.

NOTE: Do Not install a new seal until the final assembly if Step 29 will be performed.

Install bearing cone on the swash plate.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-10

STEP 25

STEP 28

A18598

A18584

Install swash plate. Shaft comes out the side of housing nearest the serial number plate.

Install the trunnion cap. Tighten the bolts to a torque of 24 to 30 Nm.

STEP 26

NOTE: Be careful not to damage the seal during installation. Wrap a thin sheet of plastic over the swash plate control arm to protect the seal.

STEP 29

A18587 Install the bearing, the original shims, the spacers, a new quad ring, and the blank trunnion cap.

NOTE: If the housing, the swash plate, or the swash plate bearings were not replaced, use the original shims.

If one or more of these items were replaced, see Step 29.

STEP 27

A18599 Remove approximately 0.12 mm of shims from each of the trunnion shim packs. Assemble the trunnion assemblies with the reduced shim packs. Tighten the bolts to a torque of 24 to 30 Nm. Move the control arm up and down while measuring the end play with a dial indicator.

Add shims to provide a 0.05 to 0.10 mm preload on the swash plate bearings. Add shims equally on each side of pump housing.

Example: Measured end play Add for preload Additional shims required

A18585 Install the bearing cup, the original shims, the spacer, and a new quad ring.

0.20 mm +0.10 mm 0.30 mm

Add one half the required shims 0.15 mm to each reduced shim pack. Assemble the trunnion sides per Steps 26 and 27.

The swash plate should move freely with a torque of 0.6 to 1.7 Nm applied to the control arm.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-11

STEP 30

STEP 33

A18582

A21067

Install the bearing and snap ring on the drive shaft. Install the drive shaft and bearing into the housing.

STEP 31

A21068 Install the inner spring seat, spring and outer spring seat (stepped seat) into the cylinder.

A18548 Install a new seal and O-ring in the seal retainer. Install the seal retainer and snap ring.

Compress the spring with the bolt and washers and install the retaining ring.

STEP 34 STEP 32

A21609 A23029 Install the thrust plate.

Install the pin retainer flush with top of cylinder. Install the pins in the recesses of the splines. Install the washer, then the retainer guide on top of the pins.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-12

STEP 35

STEP 38

A21076

A23043

Install the pistons in the slipper guide. Lubricate the pistons and cylinder block bores. Install the pistons into the cylinder block.

Install the two circuit relief valves, springs, and plugs with new O-rings. Both relief valves are the same. Tighten to a torque of 40 to 65 Nm.

STEP 36

STEP 39

A23028 Install the cylinder assembly into the housing. Turn the shaft to help align the splines. The cylinder must go into the housing until the slippers contact the thrust plate.

STEP 37

A23046 Install the needle bearing so 2 to 2.5 mm protrudes above the end cap surface. Printed end of bearing cage must face up.

A23044 Install the charge relief valve, shims, spring, and poppet into the housing with a new O-ring. Tighten to a torque of 55 to 135 Nm. See Section 6002 for adjustment procedure.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-13

STEP 40

NOTE: When the end cap is properly installed, the cylinder block spring will hold the end cap away from the housing approximately 3 mm, before the socket head screws are tightened.

Rotate the shaft to assure correct assembly. When properly assembled, a torque of 2.3 to 5.7 Nm should be required to turn the shaft.

STEP 42

A23042 Install the valve plate on the end cap with the brass side toward the pump cylinder. The cut out notch on OD locates on the roll pin in the end cap. Do not interchange valve plates.

See illustration to identify.

A23308

1

Install the coupling on the shaft. Assemble the two piston pumps using new O-rings.

1

STEP 43 2

3 238L94

1. Direction of Rotation 2. RH Drive Pump - Use This Valve Plate in Step 81.

3. LH Drive Pump - Use This Valve Plate in Step 40.

STEP 41

A23314 Tighten the socket head screws to a torque of 45 to 60 Nm. Check for proper internal assembly by slowly rotating the pump shaft while tightening these screws.

A23311 Install the end cap with a new gasket. Tighten the socket head screws to a torque of 45 to 60 Nm.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-14

RIGHT HAND DRIVE PUMP Disassembly STEP 44

STEP 47

A23308 Separate the piston pumps between the end caps. Remove the drive coupling and discard the O-rings.

STEP 45

A23043 Remove the plug, spring and circuit relief valves from both sides of the end cap. Discard the O-rings.

STEP 48

A23312 Remove the end cap. Discard the gasket.

A23024 Remove the needle bearing.

STEP 46

STEP 49

A23025 Remove the valve plate.

A23028 Remove the cylinder block assembly.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-15

STEP 50

STEP 53

A21076 Remove the pistons and slipper guide.

A21067 Remove the retaining ring. Release the spring and remove the spring seats and spring.

STEP 51 STEP 54

A21609 A23029

Remove the retainer guide, washer, pin retainer, and pins.

Remove the thrust plate.

STEP 52 STEP 55

A21068 Install a bolt and two washers to compress the spring to remove the retaining ring.

A23030 Remove the snap ring that retains the ball bearing.

Temp ate Date: 1993_02_24

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6004-16

STEP 56

STEP 59

A23031

A23033

Remove the bearing and drive shaft.

Remove the trunnion cap on the opposite side of pump.

STEP 57

STEP 60

A23032 Remove the snap ring and bearing from the drive shaft.

A23034 Remove the quad ring, the spacer, and the shims. Discard the quad ring. Record the shim sizes and the quantity.

STEP 58 STEP 61

A23038 Remove the blank trunnion cap. Discard the quad ring.

Remove the spacer, the shim or shims, and the bearing.

Record the locations for all items. Record the shim sizes and the quantity.

A23035 Remove the bearing cup.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-17

STEP 62

STEP 63

A23036

A23039

Remove the swash plate and then the bearing from the swash plate.

Remove the seal from the trunnion cap.

5

2

3

4 6 7

1

8 9 10

10

14

13 10

12

9

7

8

11 6

271L94

1.

2.

3.

4.

Swash Plate Thrust Plate Pistons Slipper Guide

5.

6.

7.

8.

Cylinder Block Trunnion Cap Quad Ring Spacer

9. Shims 10. Bearing 11. Seal 12. Coupling

13. Drive Shaft 14. Bottom Side When Installed in Machine

ILLUSTRATION RIGHT HAND DRIVE PUMP

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-18

Inspection 1. Wash all parts in cleaning solvent. Use a lint free cloth, or air dry the parts. Be careful of the machined surfaces on the parts.

NOTE: The parts must be as clean as possible for assembly.

2. Replace all O-rings, seals and gaskets. Lightly lubricate all O-rings with petroleum jelly prior to assembly. All gasket sealing surfaces must be clean before installing a new gasket.

3. Inspect the splines on the input shaft and coupling. If the splines are worn or damaged, use new parts as required.

4. Inspect both sides of the thrust plate and valve plate. If the surfaces have pitting or scoring, use new parts. Make sure that the thrust plate and valve plate are flat.

5. Inspect the area of the cylinder block that touches the valve plate. This area must be smooth and have no grooves or metal deposits.

6. Check to make sure that the pistons move freely in the cylinder block. Check for scoring and wear in the cylinder block.

7. Inspect the outer surface of the pistons. The piston shoes must be flat, smooth, and free of metal deposits. Do not try to repair the pistons or piston shoes. If there is any damage, replace the pistons.

8. Inspect the slipper guide and the thrust washer. The slipper guide must be flat and have no wear or cracks.

9. Check the cylinder block. If the spring is broken, make sure that there is no damage to the inside of the cylinder block.

10. Check the spring pin in the end cap. If the spring pin is damaged, or loose, it must be replaced.

11. Inspect the swash plate bearings and the bearing cups for flat areas, pitting, scoring, and other damage. Always install a new roller bearing and bearing cup at the same time.

12. Inspect the roller bearing in the pump housing and the needle bear ing in the pump end cap. Replace as necessary.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-19

4 5

SPRING CIRCUIT RELIEF VALVE

6 7

1 6 3

5

2 4

272L94

1. Valve Plate 2. Needle Bearing 3. Gasket

4. Plug 5. Spring

6. Circuit Relief Valve 7. Top Side When Installed in Machine

ILLUSTRATION OF END CAP FOR RIGHT HAND DRIVE PUMP

Assembly STEP 65

STEP 64

A23037

A23039 Install a new seal in trunnion cap. Seal lip goes to inside.

NOTE: Do Not install a new seal until the final assembly if Step 71 will be performed.

Install bearing cone on swash plate.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-20

STEP 66

STEP 69

1. BOSS

A23036 Install swash plate into housing. Shaft comes out opposite side from boss for mounting bracket.

A23034 Install the original shims, spacer, and new quad ring.

STEP 70 STEP 67

A23033 A23038 Install the bearing, the original shims, the spacers, a new quad ring, and the blank trunnion cap.

NOTE: If the housing, the swash plate, or the swash plate bearings were not replaced, use the original shims.

If one or more of these items were replaced, see Step 71.

STEP 68

A23035 Install the bearing cup.

Install the trunnion cap. Tighten the bolts to a torque of 24 to 30 Nm. NOTE: Be careful not to damage the seal during installation. Wrap a thin sheet of plastic over the swash plate control arm to protect the seal.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-21

STEP 71

STEP 73

A18599 Remove approximately 0.12 mm of shims from each of the trunnion shim packs. Assemble the trunnion assemblies with the reduced shim packs. Tighten the bolts to a torque of 24 to 30 Nm.

A23030 Install the snap ring that retains the ball bearings.

STEP 74

Move the control arm up and down while measuring the end play with a dial indicator.

Add shims to provide a 0.05 to 0.10 mm preload on the swash plate bearings. Add shims equally on each side of pump housing.

Example: Measured end play Add for preload Additional shims required

0.20 mm +0.10 mm 0.30 mm

A23029 Install the thrust plate.

Add one half the required shims 0.15 mm to each reduced shim pack. Assemble the trunnion sides per Steps 67, 68, 69 and 70.

The swash plate should move freely with a torque of 0.6 to 1.7 Nm applied to the control arm.

STEP 72

A23031 Install the bearing and snap ring on the drive shaft. Install the drive shaft and bearing into the housing.

Temp ate Date: 1993_02_24

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6004-22

STEP 75

STEP 77

A21067

A21076 Install the pistons in the slipper guide. Lubricate the pistons and cylinder block bores. Install pistons into the cylinder block.

STEP 78

A21068 Install the plain spring seat, spring and seat with lip.

Compress the spring with the bolt and washers. Install the retaining ring.

A23028 Install cylinder assembly into the housing. Turn the shaft to help align splines.

STEP 76

STEP 79

A21609 Install the pin retainer flush with top of cylinder. Install pins in slots of splined area. Install washer and retainer guide on top of pins.

A23024 Install the needle bearing into the valve so 2 to 2.5 mm protrudes above the end cap surface. Printed end of bearing cage must face up.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio 6004-23

STEP 80

STEP 82

A23026 Install the two circuit relief valves, springs, and plugs with new O-rings. Both relief valves are the same. Tighten to a torque of 40 to 65 Nm.

A23313 Install the end cap with a new gasket.Tighten the socket head screws to a torque of 45 to 60 Nm. NOTE: When the end cap is properly installed, the cylinder block spring will hold the end cap away from the housing approximately 3 mm, before the socket head screws are tightened.

STEP 81

Rotate the shaft to assure correct assembly. When properly assembled, a torque of 2.3 to 5.7 Nm should be required to turn the shaft.

STEP 83

A23025 Install the valve plate on the end cap with the brass side toward the pump cylinder. The cut out notch on OD locates on the roll pin in the end cap. Do not interchange valve plates.

See illustration to identify.

A23308 Install the coupling on the shaft. Assemble the two piston pumps using new O-rings.

1

2

1 3 238L94

1. Direction of Rotation 2. RH Drive Pump - Use This Valve Plate in Step 81.

3. LH Drive Pump - Use This Valve Plate in Step 40.

Temp ate Date: 1993_02_24

A t+ to disp ay temp ate i ormatio

6004-24

STEP 84

A23314 Tighten the socket head screws to a torque of 45 to 60 Nm. Check for proper internal assembly by slowly rotating the pump shaft while tightening these screws.

Section 6005

6005

DRIVE MOTORS

6005-2

TABLE OF CONTENTS TORQUE SPECIFICATIONS ......................................................................................................................................... 3 SPECIAL TOOL .......................................................................................................................................................... 3 GENERAL INFORMATION ............................................................................................................................................ 3 INSPECTION .............................................................................................................................................................. 3 DISASSEMBLY ........................................................................................................................................................... 4 Illustration of Drive Motor ........................................................................................................................................ 10 ASSEMBLY .............................................................................................................................................................. 11

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-3

TORQUE SPECIFICATIONS M8 cap screws that hold the motor together ................................................................................................................... 31 to 35 Nm M6 cap screws that fasten the seal flange to the motor housing....................................................................................... 13 to 15 Nm

SPECIAL TOOL The seal protector shown on the right is used to install the oil seal on the output shaft.

GENERAL INFORMATION If drive motor failure causes contamination in the closed loop system, it is necessary to remove the contamination from the system before fur ther operation. See Section 8003 for instructions on cleaning the system.

Read the disassembly and assembly instructions completely before you begin these procedures.

BP96F003

Be careful so that you do not damage parts that have machined surfaces.

INSPECTION

Use new seals and O-rings during assembly.

When you assemble the motor, make sure that the bench, the tools, and your hands are clean.

STEP 1

Do not use shop cloths to dry the parts. Use compressed air or towels that are free of lint.

Clean all parts in cleaning solvent. Do not use shop cloths to dry the parts. Use compressed air or towels that are free of lint.

If possible, assemble the motor in an area that is free of dust.

STEP 2 Inspect the contact areas where the rotor and the rollers touch the brake housing and the distributor plate. Check for wear, scoring, and grooves.

STEP 5 Check the outer friction discs for wear and distortion. Check the inner friction discs for wear and distortion, especially in the spline area.

STEP 3 Inspect the rollers and the lobes on the rotor for pitting, scoring, and grooves. If you find any of these defects, install a new gear set.

STEP 6

STEP 4

STEP 7

Inspect the spool for scoring and grooves. If you find either defect, install a new spool.

Before assembly, use clean hydraulic oil to lubricate all metal parts. Use petroleum jelly (vaseline) to lubricate all rubber parts.

Check the brake springs for cracks, distortion, and other damage.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-4

DISASSEMBLY STEP 8

STEP 12

Clean all dirt and grease from the motor.

STEP 9

BP96E016 Remove the seven large brake springs and the seven small brake springs from the piston housing.

BP96E013 Make alignment marks on the various sections of the motor so that you can assemble the sections correctly later.

STEP 13

STEP 10

BP96E017 Remove the O-ring from the groove in the piston housing.

BP96E014

STEP 14

Remove the seven cap screws and washers that fasten the motor together.

STEP 11

BP96E018 Remove the piston housing.

BP96E015 Remove the end cover.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-5

STEP 15

STEP 18

BP96E021 Support the edges of the piston housing on blocks and carefully drive the brake piston out of the piston housing.

BP96E019 Remove the spacer.

STEP 19 STEP 16

BP96E020 BP96E023

Remove the thrust pad.

Remove the O-ring from the brake piston.

STEP 20 STEP 17

BP96E025 BP96E024

Remove the O-ring from the brake housing.

Remove the O-ring from the piston housing.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-6

STEP 21

STEP 24

BP96E026 Remove the brake housing.

BP96E029 Remove the gear set, the distributor plate, and the drive link as an assembly.

STEP 22 STEP 25

BP96E027 BP96E030

Remove the 12 outer friction discs and the 11 inner friction discs from the brake housing.

Remove the distributor plate from the drive link.

STEP 23

STEP 26

BP96E028 Remove the O-ring from the stator.

BP96E031 Remove the drive link from the gear set.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-7

STEP 27

STEP 30

BP96E032

BP96E035

Remove the O-ring from the stator.

Remove the O-ring from the motor housing.

STEP 28

STEP 31

BP96E033

BP96E036

Remove the rotor.

Remove the spool and the two springs.

STEP 29

STEP 32

BP96E034 Remove the seven rollers.

BP96E037 Remove the two springs from the spool.

NOTE: It is recommended that you mark the rollers and the stator so that the rollers can be installed in the same recesses in the stator during assembly. Use a felt-tipped pen or some other means which will not damage the parts or leave residue in the hydrostatic system.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-8

STEP 33

STEP 36

BP96E038 Put the motor housing in a vise. Remove the six Allen head screws and washers that fasten the seal flange to the motor housing.

BP96E041 Turn the seal flange over. Use an acceptable driver to drive the dust seal and the oil seal out of the seal flange.

STEP 37 STEP 34

BP96E042 BP96E039

Remove the first thrust washer from the motor housing.

Remove the seal flange.

STEP 38 STEP 35

BP96E043 BP96E040

Remove the thrust bearing.

Remove the O-ring from the seal flange.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-9

STEP 39

STEP 42

BP96E044 Remove the second thrust washer.

BP96E048 Do not remove the bearing race unless inspection indicates that replacement is necessary.

STEP 40 STEP 43

BP96E045 Remove the output shaft from the motor housing. (The needle bearing will come with the output shaft.)

STEP 41

BP96E047 Do not remove the needle bearing from the other end of the motor housing unless inspection indicates that replacement is necessary.

STEP 44

BP96E046 Remove the needle bearing from the output shaft.

BP96E049 Check to make sure that the orifice in the drain port of the motor housing is open and clean. Do not remove the orifice unless inspection indicates that replacement is necessary.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-10

11

5 3 1

12

10

5

13

14 15 16

18 17

4

19 20

2

21 6 7

9 10

8

27

26

25

5

5

24

23 22

29 28 28

30

BS96F080

1.

2.

3.

4.

5.

6.

7.

8.

Output Shaft Dust Seal Oil Seal Thrust Washer O-Ring Allen Head Screw Washer Seal Flange

9.

10.

11.

12.

13.

14.

15.

16.

Thrust Bearing Needle Bearing Bearing Race Motor Housing Brake Housing Outer Friction Disc Inner Friction Disc Thrust Pad

17.

18.

19.

20.

21.

22.

23.

24.

Brake Piston Piston Housing Large Brake Spring Small Brake Spring Spacer Cap Screw Washer End Cover

Illustration of Drive Motor FOR EUROPEAN MACHINES ONLY

25.

26.

27.

28.

29.

30.

Gear Set Distributor Plate Drive Link Spring Spool Orifice

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-11

ASSEMBLY STEP 48

STEP 45 Before assembly, use clean hydraulic oil to lubricate all metal parts. Use petroleum jelly (vaseline) to lubricate all rubber parts.

STEP 46

BP96E048

BP96E049 If the orifice in the drain port of the motor housing was removed, install a new orifice.

If the bearing race was removed from the outer end of the motor housing, install a new bearing race. Use an acceptable driver to push the bearing race into the bore until the bearing race stops moving. The outer edge of the bearing race will extend a short distance out of the bore, as shown.

STEP 49

STEP 47

BP96E046 BP96E047

Install the needle bearing on the output shaft. Lubricate the needle bearing with petroleum jelly.

If the needle bearing was removed from the inner end of the motor housing, install a new needle bearing. The needle bearing should be flush with the face of the motor housing.

Lubricate the needle bearing with petroleum jelly.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-12

STEP 50

2

STEP 52

1 BP96F004

Mark the inner end of the output shaft as shown. The mark must be in line with the commutator slot (1) which is in line with the notch (2) at the outer end of the output shaft.

BP96E044 Install a thrust washer.

STEP 53

STEP 51

BP96E043 BP96E045 Install the output shaft straight into the motor housing. Be careful so that the output shaft does not become tilted in the bore. Push the output shaft in until it is even with the inner end of the motor housing. Make sure that the needle bearing goes all the way into the bearing race. Make sure that the output shaft turns easily with no binding.

Install the thrust bearing.

STEP 54

BP96E042 Install the last thrust washer.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-13

STEP 55

STEP 57

BP96E050 Use an acceptable driver to install a new dust seal and a new oil seal in the seal flange. The lips of the dust seal must be toward the outer end of the seal flange. The lips of the oil seal must be toward the inner end of the seal flange. Install the oil seal so that it is seated against the shoulder in the bore of the seal flange.

BP96F005 Put the seal protector (shown on page 3) in position on the output shaft. Use petroleum jelly (vaseline) to lubricate the outside of the seal protector.

STEP 58

STEP 56

BP96F006

BP96E040 Install the O-ring in the groove in the seal flange.

Use petroleum jelly to lubricate the lips of the dust seal and the oil seal. Slide the seal flange assembly over the end of the protector and into position on the output shaft. When the seal flange is in position, remove the seal protector.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-14

STEP 59

STEP 62

BP96E038 Install the six Allen head screws and washers to fasten the seal flange to the motor housing. Tighten the Allen head screws to a torque of 13 to 15 Nm.

BP96E035 Install the O-ring in the groove in the motor housing.

STEP 63

STEP 60

1 BP96F007 BP96E037

Install the drive link in the end of the output shaft.

1. This End Goes Into the Motor Housing First.

STEP 64

Install both springs on the spool.

STEP 61

BP96F008

BP96E036

Make a mark between two splines at the end of the drive link as shown. The mark must be in line with the mark you made on the output shaft in Step 50.

Install the spool and the two springs in the motor housing.

Make sure that you install the spool in the direction shown in the photograph in Step 60.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-15

STEP 65

STEP 68

BP96E034 Install the seven rollers in the recesses in the stator.

BP96F009 Put the distributor plate in position against the gear set. Make sure that the holes for the cap screws are aligned.

STEP 66 STEP 69

BP96E033 Install the rotor. Be careful so that you do not damage the surfaces of the rotor or the rollers. Do not use force to install the rotor.

BP96F010 Put the distributor plate and gear set assembly on the drive link so that the end of one of the lobes on the rotor is aligned with the mark which you made on the end of the drive link.

STEP 67

BP96E032 Find the end of the stator which will be against the distributor plate. Install the O-ring in the groove.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-16

STEP 70

STEP 73

BP96E029 Tu r n t h e d i s t r i b u t o r p l a t e a n d g e a r s e t a s s e m b l y counterclockwise until the splines on the drive link and the rotor start to mesh (approximately 15 degrees). Slide the parts together until the distributor plate is against the motor housing. Make sure that the holes for the cap screws are aligned.

BP96E053 Install an outer friction disc in the brake housing. Make sure that the recesses for the cap screws are aligned with the matching recesses in the brake housing.

STEP 74

STEP 71

BP96E054 Install an inner friction disc on the drive link.

BP96E028

STEP 75

Install the O-ring in the groove in the stator.

Alternately repeat Step 73 and Step 74 until all 12 outer friction discs and 11 inner friction discs are installed. The last friction disc installed must be an outer friction disc.

STEP 72

STEP 76

BP96E052 Install the brake housing. Make sure that the holes for the cap screws are aligned.

BP96E025 Install the O-ring in the groove in the brake housing.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 6005-17

STEP 77

STEP 80

BP96E024

BP96E020

Install the O-ring in the bore of the piston housing.

Put the thrust pad into position on the friction disc.

STEP 78

STEP 81

BP96E023

BP96E019

Install the O-ring in the groove on the piston.

Install the spacer in the hole in the thrust pad.

STEP 79

STEP 82

BP96E055 Install the piston in the piston housing so that the long end of the piston is up. You can use a soft hammer to lightly tap the piston into position, but be careful so that you do not cut the O-rings.

BP96E018 Install the piston housing on the gear set. Make sure that the spacer goes into the hole in the piston. Make sure that the holes for the cap screws are aligned.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

6005-18

STEP 83

STEP 85

BP96E017 Install the O-ring in the groove in the piston housing.

STEP 84

BP96E015 Put the end cover into position on the brake springs. Make sure that the holes for the cap screws are aligned with those in the piston housing.

STEP 86

BP96E016 Install the seven small brake springs and the seven large brake springs in the piston housing.

BP96E014 Install the seven cap screws and washers. Tighten the cap screws evenly to draw the end cover down against the piston housing. Then tighten the cap screws evenly to a torque of 31 to 35 Nm.

FOR EUROPEAN MACHINES ONLY

Section 6007

6007

SPROCKETS, CHAINS, AND AXLE HOUSINGS

6007-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 CHAIN LUBRICATION ................................................................................................................................................. 3 WHEN TO REPLACE A CHAIN ...................................................................................................................................... 3 ILLUSTRATION OF SPROCKETS, CHAINS, AND AXLES ................................................................................................. 4 CHECKING THE DEFLECTION OF A CHAIN ................................................................................................................... 5 ADJUSTING THE DEFLECTION OF THE CHAINS ........................................................................................................... 6 REMOVING A CHAIN OR AXLE HOUSING ..................................................................................................................... 7 INSTALLING A CHAIN OR AXLE HOUSING .................................................................................................................... 8 AXLE HOUSING .......................................................................................................................................................... 9 Disassembly ........................................................................................................................................................... 9 Inspection ............................................................................................................................................................. 11 Assembly .............................................................................................................................................................. 11 CROSS SECTION OF AXLE ASSEMBLY ...................................................................................................................... 15

Temp ate Date: 1994_04_05

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SPECIFICATIONS Chain compartment Oil change interval ............................................................................................................ Every 500 hours of operation or yearly Oil ........................................................................................................................................................... SAE 10W-30 engine oil Chain deflection Adjustment interval .............................................................................................. Whenever chain has 38 mm or more deflection Adjustment specification ............................................................................................................................. 6 to 25 mm deflection Special torques Wheel nuts ................................................................................................................................................................ 81 to 95 Nm Cap screws for axle housing .................................................................................................................................. 108 to 136 Nm Axle housing Bearing grease .................................................................................................................................. No. 2 wheel bearing grease

CHAIN LUBRICATION Each chain compartment is filled with 2.8 litres of 10W-30 engine oil.

After 500 hours of operation or yearly, drain the oil from the chain compartments and flush each chain compartment with clean diesel fuel. Then fill each chain compartment.

WHEN TO REPLACE A CHAIN A chain must be replaced when the axle housing cannot be moved in the slots to tighten the chain.

DO NOT remove a link to shorten the chain.

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ILLUSTRATION OF SPROCKETS, CHAINS, AND AXLES

12 22

12

11

11

11

23

10 21 20

10 19

9

18

4

8 2

17

3 14 16

15

14 13

7

6 2 5

4

3

1

BS96E112

1.

2.

3.

4.

5.

6.

Axle Seal Bearing Bearing Cup Axle Housing O-Ring

7. Seal Plate 8. Spacer 9. Rear Axle Sprocket 10. Hardened Washer 11. Nut 12. Cotter Pin

13. Cover 14. Retainer 15. Self-Aligning Bushing 16. Needle Bearing 17. Gasket 18. Thrust Washer

19. Rear Chain 20. Front Chain 21. Motor Sprocket 22. Front Axle Sprocket 23. Adjusting Screw

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CHECKING THE DEFLECTION OF A CHAIN The deflection of the chains must be checked after every 250 hours of operation.

STEP 7

STEP 2

Check the deflection of the chains. The deflection of the chains cannot be measured with accuracy. Move the chain up and down and make an estimate of the amount of deflection.

If the deflection is 38 mm or more for one chain, adjust the deflection of all chains according to the instructions on page 6.

Remove the wheel nuts and the wheels.

STEP 8

STEP 3

When the adjustment is complete, or if no adjustment was required, install the gasket for the cover. Use a new gasket if the old one was damaged.

STEP 1 Raise the wheels off the floor and use blocks to hold the machine in place.

Remove the nuts, the lock washers, and the flat washers that hold the cover for the motor sprocket.

STEP 4 Remove the cover.

STEP 5 If the gasket is damaged, remove the gasket from the cover (or the frame).

STEP 6 Check to see if any thrust washers were removed with the cover. If so, remove the thrust washers from the cover and install the thrust washers on the motor shaft.

STEP 9 Install the cover, the flat washers, the lock washers, and the nuts. The cover can be difficult to install because of the selfaligning bushing that holds the needle bearing. DO NOT use force to install the cover.

STEP 10 Install the wheels and the wheel nuts. DO NOT use an impact wrench to install the wheel nuts. Tighten the wheel nuts to a torque of 81 to 95 Nm.

STEP 11 Remove the blocks and lower the wheels to the floor.

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ADJUSTING THE DEFLECTION OF THE CHAINS NOTE: Check the deflection of the drive chains according to the instructions on page 5. If adjustment is necessary, use the following procedure:

STEP 12 Do Step 1 through Step 6 on page 5, if you have not done these steps already.

STEP 13 Loosen the cap screws for each axle housing so that the axle housing can be moved by the adjusting screw.

STEP 14 Turn the adjusting screw to move each axle housing away from the motor sprocket until the chain is too tight to let the axle housing move any farther.

STEP 15 Tighten the cap screws that hold the axle housing to a torque of 7 to 8 Nm.

STEP 16 Loosen the adjusting screws until there is approximately 1/4 inch (6 mm) clearance between the end of each adjusting screw and the axle housing.

STEP 17 Sit in the operators seat, pull down the seat bar, and start the engine. Run the engine at low idle.

STEP 18 Hold the direction control levers in the FORWARD position for 5 seconds.

STEP 19 Stop the engine.

STEP 20 Check the deflection of the chains. The chains are correctly adjusted when the deflection is 6 to 25 mm. If necessary, tighten or loosen the chains to get the correct deflection.

STEP 21 When the deflection is correct, tighten the cap screws that hold the axle housings to a torque of 108 to 136 Nm.

STEP 22 Tighten each adjusting screw against the axle housing and tighten the nuts to lock the adjusting screws into position.

STEP 23 When the adjustment is complete, install the gasket for the cover. Use a new gasket if the old one was damaged.

STEP 24 Install the cover, the flat washers, the lock washers, and the nuts. The cover can be difficult to install because of the selfaligning bushing that holds the needle bearing. DO NOT use force to install the cover.

STEP 25 Install the wheels and the wheel nuts. DO NOT use an impact wrench to install the wheel nuts. Tighten the wheel nuts to a torque of 81 to 95 Nm.

STEP 26 Remove the blocks and lower the wheels to the floor.

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REMOVING A CHAIN OR AXLE HOUSING STEP 27

STEP 34

Raise the wheels off the floor and use blocks to hold the machine in place.

Loosen the cap screws for the axle housing so that you can separate the seal plate from the frame. Separate the seal plate from the frame.

STEP 28 Remove the wheel nuts and the wheels.

STEP 35

STEP 29

Remove the cap screws and flat washers that hold the axle housing.

Remove the nuts, the lock washers, and the flat washers that hold the cover for the motor sprocket.

STEP 36

Remove the cover.

Turn the axle housing so that the long side is vertical. Move the axle housing as far as possible toward the motor sprocket.

STEP 31

STEP 37

If the gasket is damaged, remove the gasket from the cover (or the frame).

Reach through the opening for the axle sprocket and remove the chain from the axle sprocket.

STEP 32

STEP 38

Remove any thrust washers from the motor shaft.

Remove the axle housing from the machine.

STEP 33

STEP 39

Loosen the adjusting screw several turns.

Remove the chain from the motor sprocket and from the machine.

STEP 30

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INSTALLING A CHAIN OR AXLE HOUSING NOTE: If both chains are being installed on the same side, the rear chain must be installed first.

STEP 40 Check the condition of the O-ring in the groove in the axle housing. If the O-ring is damaged, install a new O-ring.

STEP 41 Install Permatex No. 2 sealer to the frame side of the seal plate.

STEP 42 Install the chain on the motor sprocket.

STEP 43 If you are installing a front chain, put the top part of the chain over the tube for the parking latch. (This tube is present even on machines which do not use the parking latch system).

STEP 44 Turn the axle housing so that the long side is vertical. Install the axle sprocket into the chain compartment.

STEP 45 Move the axle housing as far as possible toward the motor sprocket. Reach through the opening for the axle sprocket and install the chain on the axle sprocket.

STEP 46 Align the axle housing with the frame and install the cap screws and the flat washers. Tighten the cap screws just enough so that the adjusting screw can still be used to move the axle housing.

STEP 47 Turn the adjusting screw to move the axle housing away from the motor sprocket until the chain is too tight to let the axle housing move any farther.

STEP 48 Tighten the cap screws that hold the axle housing to a torque of 7 to 8 Nm.

STEP 49 Loosen the adjusting screw until there is approximately 6 mm clearance between the end of the adjusting screw and the axle housing.

STEP 50 Sit in the operators seat, pull down the seat bar, and start the engine. Run the engine at low idle.

STEP 51 Hold the direction control levers in the FORWARD position for 5 seconds.

STEP 52 Stop the engine.

STEP 53 Check the deflection of the chain. The chain is correctly adjusted when the deflection is 6 to 25 mm. If necessary, tighten or loosen the chain to get the correct deflection.

STEP 54 When the deflection is correct, tighten the cap screws that hold the axle housing to a torque of 108 to 136 Nm.

STEP 55 Tighten the adjusting screw against the axle housing and tighten the nuts to lock the adjusting screw into position.

STEP 56 If thrust washers were removed from the motor shaft, install the thrust washers.

STEP 57 Install the gasket for the cover. Use a new gasket if the old one was damaged.

STEP 58 Install the cover, the flat washers, the lock washers, and the nuts. The cover can be difficult to install because of the selfaligning bushing that holds the needle bearing. DO NOT use force to install the cover.

STEP 59 Install the wheels and the wheel nuts. DO NOT use an impact wrench to install the wheel nuts. Tighten the wheel nuts to a torque of 81 to 95 Nm.

STEP 60 Remove the blocks and lower the wheels to the floor.

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AXLE HOUSING Disassembly

STEP 64

The photographs in this procedure do not show the seal plate or the O-ring. The O-ring is installed in a groove in the axle housing.

STEP 61

B876747S Remove the axle sprocket.

STEP 65 Remove the seal plate.

B876752S

STEP 66 Remove the O-ring from the groove in the axle housing.

Remove the cotter pin.

STEP 67

STEP 62

B876766S B876751S Fasten the axle shaft in a vise and remove the nut.

Press the axle shaft, the seal, and the outer bearing out of the axle housing.

STEP 63

STEP 68

B876765S

B876748S Remove the hardened washer.

Remove the spacer.

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6007-10

STEP 69

STEP 72

B876764S Install an acceptable driver for the removal of the seal and the inner bearing.

B876761S Use an acceptable driver to press the bearing cup out of the axle housing.

STEP 73

STEP 70

Use an acceptable driver to remove the other bearing cup.

STEP 74

B876763S Press the seal and the inner bearing out of the axle housing.

B876757S

STEP 71 Remove the bearing from the first press fit area.

STEP 75

B876762S Remove the bearing cups only if inspection indicates the need for a new bearing cup or bearing. Install an acceptable puller as shown.

B876756S Remove the bearing from the second press fit area. Then remove the seal from the axle shaft.

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Inspection STEP 76

Assembly STEP 82

Use cleaning solvent to clean the bearings. Make sure that you remove all grease from the bearings.

STEP 77 Clean the grease from the bore of the axle housing.

STEP 78 Inspect the rollers of each bearing for flat areas, pitting, scoring, or other damage. If you find any damage, install a new bearing.

B876760S

STEP 79 Inspect each bearing cup for flat areas, pitting, scoring, or other damage. If you find any damage, install a new bearing cup.

Start a bearing cup into the axle housing.

STEP 83

NOTE: If you replace a bearing or a bearing cup, you must replace both parts at the same time.

STEP 80 Check for wear and damage to the splines on the axle and in the axle sprocket.

STEP 81 Check the spacer for a wear line or groove where the seal touches the spacer. If there is too much wear on a spacer, use a new spacer.

B876759S Install an acceptable driver.

STEP 84

B876758S Press the bearing cup all the way into the axle housing.

STEP 85 Use the same method to install the other bearing cup.

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STEP 86

STEP 89

B021329S Use No. 2 wheel bearing grease to fill the bearings.

B876767S Use an acceptable driver to press the seal into the axle housing. Press until the seal is even with the axle housing.

STEP 87 STEP 90

B876754S B876769S

Install a bearing in the outer bearing cup.

Start the axle shaft into the outer bearing.

STEP 88 STEP 91

B876753S Start a new seal into the axle housing.

B876770S Press the axle shaft through the first press fit area.

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STEP 92

STEP 95

B876771S Press the axle shaft all the way into the outer bearing.

B876775S Press the bearing onto the axle shaft until the bearing just touches the bearing cup.

STEP 93 STEP 96

B876772S B876776S

Use No. 2 wheel bearing grease to fill the area between the two bearings.

Install a new seal.

STEP 94

STEP 97

B876773S Install the other bearing.

B876774S Use an acceptable driver to press the seal into the axle housing. Press until the seal is even with the axle housing.

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6007-14

STEP 98

STEP 103

B876777S

B876748S

Install the spacer.

Install the hardened washer.

STEP 99

STEP 104

Install a new O-ring in the groove in the axle housing. If necessary, use petroleum jelly to hold the O-ring in position.

Remove all extra petroleum jelly from the mounting face of the axle housing.

STEP 100 Make sure that the mounting face of the axle housing and both sides of the seal plate are free of any type of lubricant.

STEP 101 B876749S

Install the seal plate.

Fasten the axle in a vise and install the nut. Tighten the nut to a torque of 27 to 34 Nm. If the hole in the axle is aligned with two of the notches in the nut, install a new cotter pin. If the hole is not aligned, tighten or loosen the nut as necessary to align the hole with the nearest pair of notches. Install the new cotter pin.

STEP 102

B876747S Install the axle sprocket so that the long end of the hub is up.

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CROSS SECTION OF AXLE ASSEMBLY 1 2

3 4

6

5 9

7

10 8

12

11

10 9 6

bt96f042

BT96F042

1. Cotter Pin 2. Nut 3. Hardened Washer

4. Axle Sprocket 5. Spacer 6. Seal

7. Seal Plate 8. O-Ring 9. Bearing

10. Bearing Cup 11. Axle Housing 12. Axle

7

Section 6008

6008

BRAKE VALVE

6008-2

TABLE OF CONTENTS BRAKE VALVE ...........................................................................................................................................................

Disassembly ...........................................................................................................................................................

Exploded View of Brake Valve ...................................................................................................................................................

Assembly ................................................................................................................................................................

FOR EUROPEAN MACHINES ONLY

3 3 4 5

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BRAKE VALVE Disassembly

STEP 4

STEP 1

BP96E005

Remove the plate from the solenoid valve.

BP96E001

STEP 5

Fasten the body of the brake valve in a vise with soft jaws.

Loosen and remove the nut.

STEP 2

BP96E006

Loosen and remove the solenoid valve from the body.

BP96E003

Remove the cover from the coil.

STEP 6 2

STEP 3

1

2 1

2

BP96E007

BP96E004

Remove and discard the O-rings (1) and backup rings (2) from the solenoid valve.

Remove the coil from the solenoid valve.

FOR EUROPEAN MACHINES ONLY

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6008-4

7

8

8

7

1

6

5

4

3 2

BS96D257

1. Body 2. Nut 3. Cover

4. Coil 5. Plate 6. Solenoid Exploded View of Brake Valve

FOR EUROPEAN MACHINES ONLY

7. O-Ring 8. Backup Ring

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Assembly

STEP 10

STEP 7 2

1

2 1

2

BP96E004

Put the coil in position on the plate.

BP96E007

Install new O-rings (1) and backup rings (2) on the solenoid valve.

STEP 11

STEP 8

BP96E003

Install the cover on the coil.

BP96E006

Lubricate the O-rings and backup rings with clean hydraulic oil. Install the solenoid valve in the body. Tighten the solenoid valve to a torque equal to 47 to 54 Nm.

STEP 12

STEP 9

BP96E002

Install the nut and tighten the nut to 7 to 8 Nm.

BP96E005

Install the plate on the solenoid valve.

FOR EUROPEAN MACHINES ONLY

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6008-6

FOR EUROPEAN MACHINES ONLY

6011 Section 6011 WHEELS AND TIRES

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6011-1

GENERAL INFORMATION Always have a qualified tire mechanic service the tires and the wheels on this machine. It is recommended that a qualified tire mechanic inflate the tires.

TIRE PRESSURE Check the air pressure and the condition of the tires every 50 hours of operation.

NOTE: It can be expected that pressure will vary +/- 10 per cent due to gauge accuracy and temperature change.

5.70 x 15, 4 ply rating, Chevron Tires ................................................................................................................................... 2.21 bar 27-8.50 x 15, 4 ply rating, Lug Type Flotation Tires ................................................................................................................ 1.65 bar 27-8.50 x 15, 6 ply rating, Lug Type Flotation Tires ................................................................................................................ 3.10 bar 27-8.50 x 15, Non-Pneumatic Tires...............................................................................................................................Not Applicable

WHEEL NUTS If the machine is new, or if you have just installed the wheels, check the wheel nuts every two hours until the wheel nuts remain tight.

The correct torque is 81 to 95 Nm.

SECTION INDEX - HYDRAULICS Section Title Section Number Removal and Installation of Hydraulic Components ....................................................................................................... 8000 Hydraulic System Troubleshooting .............................................................................................................................. 8002 Cleaning the Hydraulic System and Hydrostatic System ................................................................................................. 8003 Hydraulic Pump ....................................................................................................................................................... 8004 Loader Control Valve ................................................................................................................................................ 8005 Auxiliary Control Valve .............................................................................................................................................................. 8006 Cylinders .................................................................................................................................................................................. 8007

7

Section 8000

8000

REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

8000-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 HYDRAULIC PUMP ..................................................................................................................................................... 4 Removal ................................................................................................................................................................. 4 Installation .............................................................................................................................................................. 4 Preparing the Pump for Use ....................................................................................................................................... 4 Hydraulic Pump Installation ......................................................................................................................................................... 5 LOADER CONTROL VALVE ......................................................................................................................................... 6 Removal ................................................................................................................................................................. 6 Installation .............................................................................................................................................................. 6 Loader Control Valve Installation - Inlet, Outlet, and If Equipped, Auxiliary Hydraulic Circuit ....................................................... 7 Loader Control Valve Installation - Loader Lift Hydraulic Circuit .................................................................................................. 8 Loader Control Valve Installation - Loader Bucket Hydraulic Circuit ............................................................................................ 9 AUXILIARY CONTROL VALVE .................................................................................................................................... 10 Removal ............................................................................................................................................................... 10 Installation ............................................................................................................................................................ 10 Auxiliary Control Valve Installation ............................................................................................................................................ 11 CYLINDERS ............................................................................................................................................................. 12 Lift Cylinder .......................................................................................................................................................... 12 Removal ............................................................................................................................................................. 12 Installation .......................................................................................................................................................... 12 Loader Lift Cylinder Installation ............................................................................................................................................... 13 Bucket Cylinder ..................................................................................................................................................... 14 Removal ............................................................................................................................................................. 14 Installation .......................................................................................................................................................... 14 Loader Bucket Cylinder Installation ......................................................................................................................................... 15

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SPECIFICATIONS Weights Hydraulic pump .................................................................................................................................................................... 59 kg Loader control valve .......................................................................................................................................................... 5.89 kg Auxiliary control valve ....................................................................................................................................................... 2.62 kg Cylinders Lift cylinder .................................................................................................................................................................. 14.9 kg Bucket cylinder ............................................................................................................................................................. 6.79 kg

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8000-4

HYDRAULIC PUMP Removal

4. Connect the hoses to the hydraulic pump.

1. See Tilting the ROPS Canopy Forward in Section 9003 and do steps 1 through 10.

5. Stop the vacuum pump. Remove the vacuum pump from the hydraulic reservoir.

2. Clean the hydraulic pump and the area around the hydraulic pump.

6. Check the oil level in the hydraulic reservoir. Add oil as required.

3. Fasten identification tags to the hoses for correct installation.

7. Install the cap on the hydraulic reservoir.

4. Remove the cap from the hydraulic reservoir.

5. Connect a vacuum pump to the hydraulic reservoir.

6. Start the vacuum pump.

7. Disconnect the hoses from the hydraulic pump.

8. See Fastening the ROPS Canopy in the Operating Position in Section 9003 and do steps 1 through 6.

9. Start and run the engine at idle. If the hydraulic pump is new or had new parts, see Preparing the Pump for Use in this section.

10. Stop the engine. Check for oil leakage. Check the level of oil in the hydraulic reservoir. Add oil as required.

8. Install a plug in each hose and a cap on each fitting.

9. Stop the vacuum pump.

10. Loosen and remove the cap screws and flat washers that fasten the hydraulic pump to the piston pump.

11. Remove the hydraulic pump.

Installation 1. Put the hydraulic pump in position on the piston pump.

Install the cap screws and flat washers.

Preparing the Pump for Use 1. Make sure the loader control lever and the bucket control lever are in the NEUTRAL position.

2. Start and run the engine at 1/4 throttle for two minutes.

3. Continue to run the engine at 1/4 throttle. Put the loader control lever in the LOWER position until the loader stops moving. Continue to hold the loader control lever in the LOWER position for five seconds. Repeat this procedure for two minutes.

2. Start the vacuum pump.

4. Increase the engine speed to 1/2 throttle. Repeat the procedure which was done in step 21 for three minutes.

3. Remove the plugs from the hoses and the caps from the fittings

5. Stop the engine and check for leakage.

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sue

1

3 2

bt96f064

1. Hydraulic Pump

BT96F064

2. Piston Pump Hydraulic Pump Installation

3. Loader Control Valve

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8000-6

LOADER CONTROL VALVE Removal 1. See Tilting the ROPS Canopy Forward in Section 9003 and do steps 1 through 10.

Installation 11. Install the loader control valve. Hold the loader control valve in position and install the cap screws and flat washers. Tighten the cap screws.

2. Connect a vacuum pump to the hydraulic reservoir.

12. Start the vacuum pump.

3. Clean the loader control valve and the area around the loader control valve.

13. Remove the plugs from the tubes and the caps from the fittings.

4. Start the vacuum pump.

5. Disconnect the tubes from the loader control valve.

6. Install a plug in each tube and a cap on each fitting.

14. Connect the tubes to the fittings in the loader control valve.

15. Stop the vacuum pump. Remove the vacuum pump from the hydraulic reservoir.

7. Stop the vacuum pump.

8. Disconnect the linkage from the spools in the loader control valve.

16. Check the oil level in the hydraulic reservoir. Add oil as required.

17. Install the cap on the hydraulic reservoir.

9. Loosen and remove the cap screws and flat washers that fasten the loader control valve to the frame.

10. Remove the loader control valve.

18. Connect the linkage to the spools.

19. See Fastening the ROPS Canopy in the Operating Position in Section 9003 and do steps 1 through 6.

20. Start and run the engine at idle. Operate the loader control levers to completely extend and retract the lift and buckets cylinders to remove any air from the hydraulic system.

NOTE: It can be possible for the spools in the loader control valve to bind when operated. If the spools bind, loosen and retighten the valve mounting bolts to a lower torque valve.

21. Lower the loader bucket to the floor. Stop the engine.

22. Check for oil leakage. Check the level of oil in the hydraulic reservoir. Add oil as required.

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sue

A 2

3 1

A

3 BT96F065

1. Loader Control Valve

2. Hydraulic Pump

3. To Auxiliary Control Valve (If Equipped)

Loader Control Valve Installation - Inlet, Outlet, and If Equipped, Auxiliary Hydraulic Circuit

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8000-8

1

BT96F066

1. Loader Control Valve Loader Control Valve Installation - Loader Lift Hydraulic Circuit

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1

BT96F067

1. Loader Control Valve Loader Control Valve Installation - Loader Bucket Hydraulic Circuit

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8000-10

AUXILIARY CONTROL VALVE Removal 1. See Tilting the ROPS Canopy Forward in Section 9003 and do steps 1 through 10.

Installation 1. Install the auxiliary control valve. Hold the auxiliary control valve in position and install the bolts, flat washers, lock washers, and nuts. Tighten the nuts.

2. Connect a vacuum pump to the hydraulic reservoir.

2. Start the vacuum pump.

3. Clean the auxiliary control valve and the area around the auxiliary control valve.

4. Disconnect the foot pedal linkage from the auxiliary control valve.

5. Fasten identification tags to the hoses for the auxiliary control valve.

6. Start the vacuum pump.

7. Disconnect the hoses from the auxiliary control valve.

3. Remove the plugs from the hoses and the caps from the fittings.

4. Connect the hoses to the fittings in the control valve.

5. Stop the vacuum pump.

6. Connect the foot pedal linkage to the auxiliary control valve.

7. Check the oil level in the hydraulic reservoir. Add oil as required.

8. Install a plug in each hose and a cap on each fitting.

9. Stop the vacuum pump.

10. Hold the auxiliary control valve and loosen and remove the nuts, lock washers, flat washers, and bolts that fasten the auxiliary control valve to the front panel.

8. See Fastening the ROPS Canopy in the Operating Position. Do steps 1 through 6.

9. Start and run the engine at idle. Operate the auxiliary foot pedal.

10. Stop the engine.

11. Remove the auxiliary control valve.

11. Check for oil leakage. Check the level of oil in the hydraulic reservoir. Add oil as required.

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1

2

BT96F068

1. Auxiliary Control Valve

2. Loader Control Valve

Auxiliary Control Valve Installation

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8000-12

CYLINDERS Lift Cylinder Removal

Installation 1. Hold the lift cylinder in place. Install the pivot pin at the closed end of the lift cylinder.

1. Clean the lift cylinder and the fittings for the lift cylinder.

2. Connect the hoses to the tubes on the lift cylinder.

2. Start and run the engine at half throttle. Raise the loader completely.

3. Start and run the engine at idle. Move the loader control lever to completely extend the lift cylinder.

3. Fasten a chain hoist to the loader bucket to support the loader while the lift cylinder is removed.

4. Stop the engine. Move the loader control levers in all directions to release any circuit pressure.

5. Fasten identification tags to the hoses that are connected to the lift cylinder.

6. Disconnect the hoses from the tubes at the lift cylinder.

Install caps on the hoses and plugs in the tubes.

7. The weight of the lift cylinders is approximately 14.94 kg.

Hold the lift cylinder in place and remove the pivot pin from the rod end of the lift cylinder. If you are removing the right lift cylinder, also remove the support strut.

!

WARNING: Do not use your fingers to check the alignment of the cylinder rod. Personal injury can be the result.

48-88

4. Have another person align the rod end of the lift cylinder with the loader frame. Install the pivot pin. If you are installing the right lift cylinder, also install the support strut.

5. Disconnect the chain hoist from the loader bucket.

Operate the loader control levers to completely extend and retract the lift cylinders several times to remove any air from the hydraulic system.

8. Lower the rod end of the lift cylinder to the fender.

6. Lower the loader bucket to the floor. Stop the engine.

9. Remove the pivot pin from the closed end of the lift cylinder and remove the lift cylinder from the machine.

7. Check for oil leakage. Check the oil level in the hydraulic reservoir. Add oil as required.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8000-13

1

BT96F069

1. Loader Lift Cylinder Loader Lift Cylinder Installation

Temp ate Date: 1994_04_05

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8000-14

Bucket Cylinder Removal

Installation 1. Hold the bucket cylinder in place. Install the pivot pin at the closed end of the bucket cylinder.

1. Clean the bucket cylinder and the fittings for the bucket cylinder.

2. Connect the hoses to the fittings on the bucket cylinder.

2. Operate the loader control levers to completely dump the bucket and lower the bucket to the floor.

3. Start and run the engine at low idle. Move the loader control lever to raise the loader frame until the bucket is clear of the floor.

3. Stop the engine. Move the loader control levers in all directions to release any circuit pressure.

4. Fasten identification tags to the hoses that are connected to the bucket cylinder.

!

WARNING: Do not use your fingers to check the alignment of the cylinder rod. Personal injury can be the result.

48-88

5. Disconnect the hoses from the fittings in the bucket cylinder. Install caps on the hoses and plugs on the fittings.

6. Remove the pivot pin from the rod end of the bucket cylinder.

7. The weight of the bucket cylinder is approximately 6.79 kg. Hold the bucket cylinder in place and remove the pivot pin from the closed end of the bucket cylinder.

4. Have another person align the rod end of the bucket cylinder with the bucket. Install the pivot pin.

5. Operate the loader control to completely extend and retract the bucket cylinders several times to remove any air from the hydraulic system.

6. Check for oil leakage. Check the oil level in the hydraulic reservoir. Add oil as required.

Temp ate Date: 1994_04_05

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1

BT96F070

1. Loader Bucket Cylinder Loader Bucket Cylinder Installation

7

8002 HYDRAULIC SPECIFICATIONS AND TROUBLESHOOTING

8002

Section

8002-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 SPECIAL TOOLS ........................................................................................................................................................ 3 TROUBLESHOOTING PROCEDURES ...........................................................................................................................

Problem in All Circuits ..............................................................................................................................................

Problem in a Loader (Lift or Bucket) Circuit ..................................................................................................................

Problem in an Auxiliary Circuit ...................................................................................................................................

Problem in a Steering Circuit .....................................................................................................................................

4 4 5 5 5

MAIN RELIEF VALVE .................................................................................................................................................. 6 Pressure Check ....................................................................................................................................................... 6 Adjustment ............................................................................................................................................................. 6 PUMP OUTPUT TEST .................................................................................................................................................. 8 SEQUENCE VALVE ..................................................................................................................................................... 9 Pressure Check ....................................................................................................................................................... 9 Adjustment ............................................................................................................................................................. 9 HYDRAULIC FILTER ................................................................................................................................................. 10 HYDRAULIC PUMP ................................................................................................................................................... 11 LOADER CONTROL VALVE ....................................................................................................................................... 12 DRIVE MOTORS ....................................................................................................................................................... 13 AUXILIARY CONTROL VALVE .................................................................................................................................... 14

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

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SPECIFICATIONS Hydraulic Pump Output ................................................................................................................36.3 L/min at 2400 r/min at 138 bar Main Relief Valve (in loader control valve) ........................................................................................ 158.6 to 172.4 bar at full throttle Sequence Valve .........................................................................................................................................................29.3 to 32.8 bar Loader Cycle Time [with rated load of 318 kg] Raise ........................................................................................................................................................................ 4.1 seconds Lower (power down) ................................................................................................................................................. 2.5 seconds Bucket Roll Back ...................................................................................................................................................... 1.6 seconds Bucket Dump (strike plane level to full dump)............................................................................................................. 1.2 seconds One Way Orifice Plate (restricts return flow to loader lift B port) Orifice size ...................................................................................................................................................................... 4.6 mm Temperature of Hydraulic Oil During Testing .......................................................................................... operating temperature 52°C

IMPORTANT: There is no charge pump on this machine. Charge oil for the closed loop hydrostatic system is supplied by return oil from the gear pump hydraulic system. DO NOT run the engine if the return oil from the gear pump hydraulic system is not providing adequate charge oil flow. DO NOT make any test connections or flowmeter connections which will prevent the flow of this return oil/charge oil.

SPECIAL TOOLS

B785789M

Flowmeter

B009638M

Pressure Test Fitting Kit

B797157M

Flowmeter Fitting Kit

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

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8002-4

TROUBLESHOOTING PROCEDURES Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts.

Check the oil level in the hydraulic reservoir. Is the oil level correct?

NO

Fill the hydraulic reservoir with the oil specified in Section 1002.

NO

Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

YES

See Section 9000 and check the control linkages. Check the operation of the machine again. Does the machine operate correctly?

YES Troubleshooting complete.

Problem in All Circuits Replace the hydraulic filter.

See Section 8003 and check for contaminated oil. Is the oil contaminated?

NO

See page 6 and check the pressure setting of the main relief valve. Is the pressure setting correct?

YES

NO YES Adjust the main relief valve.

See Section 8003. Clean or replace the oil.

See page 8. Do the pump output test. Is the pump good?

NO YES

Repair or replace the hydraulic pump.

See the following topics for other circuits.

FOR EUROPEAN MACHINES ONLY

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Problem in a Loader (Lift or Bucket) Circuit Run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

NO

See Section 8005. Disassemble the loader control valve and check for worn or damaged parts.

YES

Check the cylinder piston packing. Is the cylinder piston packing good?

NO

See Section 8007 and repair the cylinder.

YES

See Section 8005. Disassemble the loader control valve and check for worn or damaged parts.

Problem in an Auxiliary Circuit NOTE: If the problem is in all auxiliary circuits, check the O-ring at the power beyond fitting in the loader control valve. If the O-ring is good, continue with the troubleshooting procedure below.

Run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

NO

See Section 8006. Disassemble the auxiliary control valve and check for worn or damaged parts.

YES

Check the cylinder piston packing. Is the cylinder piston packing good?

NO

See Section 8007 and repair the cylinder.

YES

See Section 8006. Disassemble the auxiliary control valve and check for worn or damaged parts.

Problem in a Steering Circuit See page 9 and check the pressure setting of the sequence valve. Is the pressure setting correct?

NO

Adjust the sequence valve.

YES

See Section 6002 and check the hydrostatic system.

FOR EUROPEAN MACHINES ONLY

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8002-6

MAIN RELIEF VALVE Pressure Check 1. Park the machine on a level surface. Lower the loader bucket to the floor.

2. The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

4. Run the engine at full throttle. Hold the lift control lever in the LOWER position. Do not put the lift control lever in the FLOAT position. Continue to hold the lift control lever in the LOWER position while you read the pressure gauge.

Then release the lift control lever and decrease the engine speed to low idle. Stop the engine.

5. Compare the reading with the specification on page 3. If the reading is not correct, adjust the main relief valve.

Adjustment The main relief valve is in the loader control valve. See page 12 for the location. Use pliers to remove the cap from the main relief valve. After you adjust the main relief valve, do the pressure check again to make sure that the setting is correct.

3. See the illustration on page 7. Use a pressure gauge with a capacity of at least 207 bar. Disconnect the tube from the fitting at Test Point 1. Connect the pressure gauge to the tube. Install a cap on the fitting.

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

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3

4

1

2

BS96E066

1. Test Point 1 (9/16-18 JIC). Connect Pressure Gauge to Tube. Install Cap on Fitting.

2. Loader Control Valve

FOR EUROPEAN MACHINES ONLY

3. Left-Hand Lift Cylinder 4. Right-Hand Lift Cylinder

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8002-8

PUMP OUTPUT TEST

!

WARNING: Two persons are required to perform the flowmeter tests for safety to avoid possible injury. One person must be seated in the operators seat with the Seat Bar down when the engine is running. The second person is to control the CSM118 flowmeter and take the readings.

8. Divide the flow reading at 138 bar by the flow reading in step 5. This answer multiplied by 100 is the percent efficiency of the pump. If the efficiency of the pump is less than 75%, repair or replace the pump. If the efficiency of the pump is more than 75%, the pump is good.

2 1. Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

1 2. See the illustration. Disconnect the hose from the 45 degree fitting at Test Point 2. Install a plug in the hose.

Connect the flowmeter inlet hose to the 45 degree fitting (1-1/16 - 12 JIC).

3. See the illustration. Find the return tube from the loader control valve. Remove the cap from the fitting on the return tube. Connect the flowmeter outlet hose to the fitting (7/8 - 14 JIC).

6

9

IMPORTANT: There is no charge pump in the piston pumps. The flowmeter outlet hose must be connected to the retur n tube as shown so that charge circuit oil is provided to the piston pumps during this test. DO NOT c o n n e c t t h e fl ow m e t e r o u t l e t h o s e t o t h e hy d ra u l i c reservoir.

5

7 3

4

4. The oil must be at operating temperature. If the oil is not at operating temperature, run the engine at full throttle and close the pressure valve of the flowmeter until the pressure gauge indicates 103 bar. Continue to run the engine until the temperature of the oil is 52°C.

bt96b110

BT96B110

5. Run the engine at 2400 rpm (r/min). Completely open the load valve on the flowmeter. Read the flow gauge and record the flow reading.

1.

2.

6. Continue to run the engine at 2400 rpm (r/min). Slowly close the load valve until the pressure is 138 bar. Make sure that the engine is still running at 2400 rpm (r/min).

Read the flow gauge and record the flow reading.

3.

4.

5.

6.

7.

8.

7. Decrease the engine speed to low idle and stop the engine.

8

9.

Hydraulic Pump Test Point 2. Disconnect Hose from 45 Degree Fitting. Connect Flowmeter Inlet Hose to the 45 Degree Fitting (1-1/16 - 12 JIC).

Loader Control Valve To Oil Cooler From Hydraulic Reservoir Piston Pumps Cap Fitting (7/8 - 14 JIC). Connect Flowmeter Outlet Hose Here.

To Sequence Valve

FOR EUROPEAN MACHINES ONLY

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SEQUENCE VALVE Pressure Check

5. Compare the reading with the specification on page 3. If the reading is not correct, adjust the sequence valve.

1. Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

Adjustment

2. The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds.

See the following illustration. The sequence valve is below the floor plate. Remove the cap from the sequence valve for access to the adjusting screw. After you adjust the sequence valve, do the pressure check again to make sure that the setting is correct.

B. Put the bucket control lever in the NEUTRAL position for 10 seconds.

1

C. Repeat steps A and B until the temperature of the oil is 52°C or the side of the reservoir is very warm.

3. See the following illustration. The sequence valve is below the floor plate. Use a pressure gauge with a capacity of at least 207 bar. Remove the cap from the tee at Test Point 3. Connect the pressure gauge to the tee.

The pressure gauge must be accurate in the range of 27 to 35 bar.

4. Run the engine at full throttle. Make sure that all control levers are in the NEUTRAL position. Leave the control levers in the NEUTRAL position while you read the pressure gauge. Then decrease the engine speed to low idle. Stop the engine.

2 4 5

3

6

7 BT96B112

1. Sequence Valve 2. Pressure Reducing Valve 3. Test Point 3. Remove Cap. Connect Pressure Gauge to Tee. 4. To Loader Control Valve 5. From Hydraulic Pump 6. To Brake Valve 7. Return to Hydraulic Tank

FOR EUROPEAN MACHINES ONLY

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8002-10

HYDRAULIC FILTER 4

2

5

1

2 1 4 3 1050L93B

1.

2.

3.

4.

5.

Inlet Outlet Cold Oil By-Pass Valve Filter Condition Indicator Switch Filter

5

bt96b040

BT96B040

FOR EUROPEAN MACHINES ONLY

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HYDRAULIC PUMP 2

4 3

1

1050L93C

3 4

1

2 5 1.

2.

3.

944L93

Inlet Outlet Gear Pump

4.

5.

Drive Shaft Inlet Passage from Case Drain of Piston Pumps

FOR EUROPEAN MACHINES ONLY

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8002-12

LOADER CONTROL VALVE 6

4

7

4

10

2

1

3 5 9

8 4

1. Inlet 2. Power Beyond, If Equipped with Auxiliary Hydraulics 3. Return

1

4. Load Check Valve 5. Main Relief Valve.

Remove Cap for Adjustment 6. To Bucket Cylinders

7.

8.

9.

10.

To Lift Cylinders Bucket Spool Lift Spool One Way Orifice Plate

6 5

6

8

9

bt96b041

3

7 2

FOR EUROPEAN MACHINES ONLY

7 BT96B041

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DRIVE MOTORS

2 1.

2.

3.

4.

5.

6.

7.

8.

1

4

Inlet/Outlet Motor Spool Case Drain Brake Brake Springs Brake Release Pressure Brake Drain

5 3 1

1

6

7

8

2

7

5

8

6

3

4

7

1

BT96B113

FOR EUROPEAN MACHINES ONLY

Temp ate Date: 1994_04_05

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8002-14

AUXILIARY CONTROL VALVE 3

4

1

1.

2.

3.

4.

5.

6.

7.

2

Inlet Outlet A Port B Port Spool Spring Load Check Valve

7 5 7

6 3

4

1 6

5

bt96b043

2

FOR EUROPEAN MACHINES ONLY

BT96B043

8003 CLEANING THE HYDRAULIC SYSTEM AND HYDROSTATIC SYSTEM

8003

Section

8003-2

TABLE OF CONTENTS GENERAL INFORMATION ............................................................................................................................................ 3 TYPES OF CONTAMINATION ....................................................................................................................................... 3 CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 4 FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 5 CLEANING THE HYDROSTATIC SYSTEM ...................................................................................................................... 6 CHANGING THE HYDRAULIC OIL AND FILTER .............................................................................................................. 6

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GENERAL INFORMATION Contamination in the hydraulic system or hydrostatic system is a major cause of malfunction of components.

Contamination is any foreign material in the hydraulic oil.

Contamination can enter the hydraulic and hydrostatic system in any of the following ways: 1. When you drain the hydraulic oil or disconnect a line.

2. When you disassemble components.

hydraulic

or

hydrostatic

3. From normal wear of the components.

4. From damaged components.

The best way to remove contamination from the hydraulic system is to use the por table filter. See Cleaning the Hydraulic System beginning on page 4.

T h e b e s t way t o r e m ove c o n t a m i n a t i o n f r o m t h e hydrostatic system is to disassemble the components and clean the system. See Cleaning the Hydrostatic System beginning on page 6.

TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. These particles are too small to see or feel. Mircroscopic contamination can be found by the identification of the problems the microscopic contamination causes, or by testing in a laboratory. Examples of problems caused by microscopic contamination include the following:

Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of a component. Examples of visible contamination include the following: 1. Particles of metal or dirt in the oil.

2. Air in the oil.

1. Cylinder rod seals leak.

3. Odor of burned oil.

2. Control valve spools do not return to neutral.

4. Water in the oil.

3. The hydraulic system has a high operating temperature.

4. Rapid wear of the components.

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8003-4

CLEANING THE HYDRAULIC SYSTEM 1. Prepare the portable filter shown on page 2 by doing the following steps.

A. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter.

10. Install the valve, from the fitting kit, into the drain plug hole. Make sure that the valve is closed.

11. Stop the vacuum pump.

12. Connect the inlet hose of the portable filter to the valve.

B. Remove the filter element from the portable filter.

13. Disconnect the vacuum pump.

C. Remove all hydraulic oil from the portable filter.

14. Put the return hose of the portable filter into the reservoir.

D. Clean the inside of the housing for the filter element.

15. Open the valve in the bottom of the reservoir.

E. Install a new filter element in the portable filter.

16. Move the switch for the portable filter to the ON position.

2. Determine whether the contamination is microscopic or visible. See types of Contamination of page 3.

3. If the contamination is microscopic, do the following: A. Check the maintenance schedule for the machine to learn whether or not the hydraulic oil must be changed. If necessary, change the hydraulic oil. See page 6.

B. Do steps 6 through 36.

17. Start and run the engine at half throttle.

18. Run the portable filter for 10 minutes with the engine running at half throttle.

19. Do the following to heat the oil to operating temperature.

A. Increase the engine speed to full throttle.

B. Hold the bucket control lever in the ROLLBACK position for 30 seconds.

4. If the contamination is visible, do the following steps: A. Change the hydraulic oil. See page 6.

B. Do steps 5 through 36.

5. Check the amount of contamination in the hydraulic system by doing the following steps: A. Disassemble one cylinder in each circuit. Check for damage to the seals, scoring of the cylinder walls, etc. Repair the cylinders as necessary.

B. If, in your judgment damage to the cylinders was caused by severe contamination and is not the result of normal wear, it is necessary to remove, clean, and repair all valves, pump, lines, cylinders, etc. in the hydraulic system.

C. Return the bucket control lever to NEUTRAL for 15 seconds.

D. Repeat steps 19B and 19C until the oil is at operating temperature.

20. With the engine running at full throttle and the portable filter running, completely extend and retract the lift cylinders and the bucket cylinders. Continue to operate the cylinders two times, one after the other, for 30 minutes.

21. Decrease the engine speed to low idle.

22. Continue to run the portable filter for 10 minutes. During this time, move the hose up and down in the reservoir to help mix the oil in the reservoir.

6. Remove the dip stick from the reservoir.

23. Stop the portable filter.

7. Connect a vacuum pump to the reservoir.

24. Stop the engine.

8. Start the vacuum pump.

25. Remove the hose from the reservoir.

9. The reservoir is on the right side of the machine. Loosen and remove the drain plug from the bottom of the reservoir.

26. Connect the vacuum pump to the reservoir.

27. Close the valve in the bottom of the reservoir.

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28. Disconnect the inlet hose from the valve.

33. Disconnect the vacuum pump from the reservoir.

29. Start the vacuum pump.

34. Install the dipstick cap.

30. Loosen and remove the valve.

35. Replace the hydraulic filter.

31. Install and tighten the drain plug.

36. Check the level of oil in the reservoir and add oil as required.

32. Stop the vacuum pump.

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at half throttle.

6. Disconnect the hydraulic lines from the closed ends and the rod ends of all cylinders.

2. Operate the control levers to retract all cylinder rods.

!

WARNING: If retracting the cylinder rods causes the attachment to be raised, block the attachment in place before proceeding to the next step.

39-4

3. Change the hydraulic oil according to the instructions on page 6.

4. Change the hydraulic filter.

5. You will be disconnecting the hydraulic lines from the cylinders in the next step. Before you disconnect any hydraulic lines, make sure that the attachments will not fall. Put supports under the attachments as required.

Move all control levers in both directions to relieve any circuit pressure.

NOTE: Check the hydraulic oil level frequently while you do steps 7 and 8. Have another person hold a container under the hydraulic lines while you do step 8.

7. Start and run the engine at low idle.

8. Move each control lever in both directions until clean hydraulic oil flows from each hydraulic line.

9. Stop the engine.

10. Connect the hydraulic lines to the closed ends of the cylinders.

11. Start and run the engine at low idle.

12. Move each control lever in both directions until clean oil flows from each hydraulic line.

13. Stop the engine.

14. Connect the hydraulic lines to the rod ends of the cylinders.

15. Check the hydraulic oil level. Add hydraulic oil as required.

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8003-6

CLEANING THE HYDROSTATIC SYSTEM The hydrostatic system is a closed loop. Any contamination in the hydrostatic system will stay in the closed loop. If a component, hose, or tube in the hydrostatic system is removed for any reason, you must clean the hydraulic system. If any contamination is left in the closed loop, the contamination will damage the components in the hydrostatic system.

3. Clean all hoses and tubes in the hydrostatic system.

Remove each hose and tube from the machine. Flush and clean with diesel fuel or cleaning solvent. Hoses and tubes must be dry before being installed.

1. See Section 6000. Remove the piston pumps and motors.

5. Make sure the hydraulic system is clean so that the charge pump will not cause new contamination in the closed loop. Clean the hydraulic system as required.

2. Disassemble, clean and inspect the piston pumps and motors. See Section 6004 for piston pumps and 6005 for the motors.

4. See Section 6000 and install the piston pumps and motors.

CHANGING THE HYDRAULIC OIL AND FILTER 1. Clean the filler cap and the area around the filler cap.

2. Remove the filler cap.

3. The hydraulic reservoir capacity is approximately 28.1 litres with filter change.

4. Find the drain plug at the bottom of the hydraulic reservoir. Loosen and remove the drain plug and drain the oil from the hydraulic reservoir.

5. Change the hydraulic filter.

6. Clean the hydraulic filter and area around the hydraulic filter.

7. Turn the hydraulic filter counterclockwise and remove the hydraulic filter.

8. Lubricate the O-ring on the new hydraulic filter with clean oil.

9. Install the new hydraulic filter. Tighten the hydraulic filter manually 1/2 to 3/4 turn after the O-ring contacts the filter head. DO NOT use a wrench to tighten the hydraulic filter.

10. Install and tighten the drain plug.

11. Fill the hydraulic reservoir with oil. See Section 1002 for the correct oil.

12. Install the filler cap.

13. Start the engine and run the engine at low idle. Check for oil leakage at the filter and the drain plug.

14. Stop the engine. Check the level of the oil in the hydraulic reservoir. Add oil as required.

Section

HYDRAULIC PUMP

8004

8004

8004-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 2 SPECIAL TORQUES .................................................................................................................................................... 2 DISASSEMBLY ........................................................................................................................................................... 3 INSPECTION .............................................................................................................................................................. 4 ASSEMBLY ................................................................................................................................................................ 5

SPECIFICATIONS Hydraulic pump output ................................................................................................................. 36.3 L/min at 2400 r/min at 138 bar Manufacturer...........................................................................................................................................................Sauer Sundstrand Port threads Inlet port .............................................................................................................................. 1-5/16 inch-12 straight thread, O-ring Outlet port............................................................................................................................ 1-1/16 inch-12 straight thread, O-ring

SPECIAL TORQUES Hex head screws..............................................................................................................................................................61 to 68 Nm

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DISASSEMBLY STEP 1

STEP 4

A23318 Make alignment marks across the sections so the sections can be assembled correctly.

A23322 Remove main body.

NOTE: Gears and bearing blocks must be assembled in same orientation as they are disassembled.

STEP 2

STEP 5

A23320 Remove cover bolts and remove front cover.

A23324 Remove drive gear, driven gear, and rear bearing block.

STEP 3

STEP 6

A23321 Remove front bearing block.

A23326 Remove seals from rear cover.

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8004-4

STEP 7

A23330 Remove seals from front cover.

INSPECTION STEP 8

STEP 10

Clean all parts in cleaning solvent.

Inspect the main body for excessive wear and damage.

STEP 9

A23324 Inspect the gears and bearing blocks for excessive wear and damage.

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ASSEMBLY STEP 11

STEP 13

A23383

A23320

Assemble new seals in front and rear covers.

Install front cover.

STEP 12

STEP 14

A23334 Set main body on rear cover and install bearing blocks and gears in same orientation as they were disassembled.

A23336 Torque cover bolts to 61 to 68 Nm.

7

Section 8005

8005

LOADER CONTROL VALVE

8005-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 2 LOADER CONTROL VALVE ......................................................................................................................................... 3 Disassembly ........................................................................................................................................................... 3 Inspection .............................................................................................................................................................. 6 Exploded view of loader control valve ......................................................................................................................................... 7 Assembly ............................................................................................................................................................... 8 Cross section of loader control valve ........................................................................................................................................ 12

SPECIFICATIONS Manufacturer ........................................................................................................................................................................ Danfoss Pressure setting of main relief valve ................................................................................................................. See Section 8002 Spool travel Bucket spool, neutral to pressure ..................................................................................................................... 6.4 mm in and out Lift spool, neutral to pressure ........................................................................................................................... 6.4 mm in and out Lift spool, neutral to float ................................................................................................................................................. 11.9 mm Spool in .......................................................................................................................................................... Pressure at A port Spool out ............................................................................................................................................................. Pressure at B port Port threads Work ports ............................................................................................................................ 3/4 inch - 16 straight thread, O-ring Inlet and Outlet ports ............................................................................................................ 7/8 inch - 14 straight thread, O-ring Special torques Detent stud ..............................................................................................................................................................2.7 to 4.1 Nm Screw for bucket spool .............................................................................................................................................2.7 to 4.1 Nm Screws for spring cap ...............................................................................................................................................2.7 to 4.1 Nm Detent plugs ............................................................................................................................................................2.7 to 4.1 Nm Relief valve ................................................................................................................................................................41 to 47 Nm Load Check valve plug ...............................................................................................................................................34 to 41 Nm

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LOADER CONTROL VALVE Disassembly STEP 1

STEP 4

B5802289M

B5803089M

Loosen the plugs on the detent housing.

Remove the detent housing.

STEP 2

STEP 5

B5802489M

B5803289M

Remove the plugs, springs, and steel balls from the detent housing.

Remove the lift spool assembly from the body.

STEP 3

STEP 6

B5802889M Loosen and remove the screws and lock washers that fasten the detent housing to the body.

B5803489M Remove the O-rings from both ends of the spool bore.

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8005-4

STEP 7

STEP 10

B5811689M

B5813289M

Loosen and remove the screws and lock washers that fasten the spring cap to the body.

Remove the O-rings from both ends of the spool bore.

STEP 8

STEP 11

B5811889M

B5820289M

Remove the spring cap.

Remove the main relief valve from the body.

STEP 9

STEP 12

B5812089M Remove the bucket spool assembly from the body.

B5820489M Loosen the plug for the load check valve.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8005-5

STEP 13

STEP 17 1

B5820689M Remove the plug, spring, and poppet for the load check valve from the body.

B5821289M 1. O-Ring Remove the O-rings from the load check plugs.

STEP 14 Repeat steps 12 and 13 for the other load check valve.

STEP 18

STEP 15

1

2

B5822089M

B5820889M

1. Backup Ring 2. O-Ring

Hold the lift spool and remove the detent stud, spring retainer, spring, and spring seat from the lift spool. Push against the spring as the detent stud is removed to prevent sudden spring expansion.

Remove the O-rings and backup rings from the main relief valve.

STEP 16

STEP 19

1

B5821889M Hold the bucket spool and remove the screw, flat washer, spring retainer, spring, and spring seat from the bucket spool.

B5821489M 1. O-Ring Remove the O-ring from the detent stud.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

8005-6

Inspection 1. Clean all parts in cleaning solvent.

2. Inspect the spools for scoring and excessive wear. If a spool is damaged or excessively worn, the complete valve must be replaced.

3. Inspect spool bores for scoring and excessive wear. If a spool bore is damaged or excessively worn, the complete valve must be replaced.

4. Inspect the main relief valve for damage. Use a new main relief valve as required.

5. Inspect the load check plugs, springs, and poppets for damage or excessive wear. Use new parts as required.

6. Inspect the remaining parts of the loader control valve for damage or excessive wear. Use new parts as required.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8005-7

1

2

1 3

3 4

6

2

4 5

5

3

2 3 7 3 8

3

17

3 10

9 11

3 18 14

4

19

16

12 21

15

14

20

13

22

14 1 B890694J

1.

2.

3.

4.

5.

Load Check Valve Plug O-Ring Spring Poppet

6.

7.

8.

9.

10.

Restrictor Body Main Relief Valve Backup Ring Bucket Spool

11.

12.

13.

14.

15.

16.

Spring Seat Spring Retainer Flat Washer Screw Spring Cap Lock Washer

Exploded View of Loader Control Valve

17.

18.

19.

20.

21.

22.

Lift Spool Detent Stud Detent Housing Steel Ball (2) Plug (2) Spring (2)

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

8005-8

Assembly STEP 23

STEP 20

1

B5820689M

B5821489M 1. O-Ring

Install the poppets, springs, and plugs for the load check valve in the body. Make sure that the end of the poppet with the slot is toward the plug.

Install a new O-ring on the detent stud.

STEP 21

STEP 24 1

2

B5820889M

1. Backup Ring 2. O-Ring

B5820489M Tighten the plugs to 34 to 41 Nm.

Install the O-rings and backup rings from the main relief valve.

STEP 22

STEP 25 1

B5821289M 1. O-Ring Install the O-rings from the load check plugs.

B5820289M Lubricate the O-rings and backup rings on the main relief valve with clean oil. Install the main relief valve in the body.

Tighten the relief valve to41 to 47 Nm.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8005-9

STEP 26

STEP 29

B5813489M Install a new O-ring in the groove at the eye end of the bucket spool bore.

Tighten the screws to 2.7 to 4.1 Nm.

STEP 27

STEP 30

B5813089M Lubricate the bucket spool and the bucket spool bore with clean oil. Install the bucket spool from the spring end of the body, eye end first. Push the bucket spool into the bore until the other O-ring can be installed in the groove at the spring end of the bucket spool bore. Install a new O-ring in the groove.

STEP 28

B5812489M Push the bucket spool into the body until the spring end of the bucket spool is even with the bucket spool bore. Apply 242 Loctite to the threads in the spool. Install the spring seat, spring, spring retainer, flat washer, and screw on the bucket spool.

B5812289M

B5811889M Install the spring cap.

STEP 31

B5811689M Install the lock washers and screws. tighten the screws to 92.7 to 4.1 Nm.

Temp ate Date: 1994_04_05

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8005-10

STEP 32

STEP 34

B5810989M Install a new O-ring in the groove at the eye end of the lift spool bore.

STEP 33

B5811089M Push the lift spool into the body until the spring end of the lift spool is even with the lift spool bore. Apply a small amount of petroleum jelly to the spring seat to hold the spring seat in position on the lift spool. Put the spring seat in position on the lift spool.

STEP 35 Apply Loctite 242 to the threads in the spool.

STEP 36

B5803489M Lubricate the lift spool and lift spool bore with clean oil. Install the lift spool from the spring end of the body, eye end first.

Push the lift spool into the bore until the other O-ring can be installed in the groove at the spring end of the lift spool bore.

Install a new O-ring in the groove.

B58111489M Hold the lift spool in place and install the spring, spring retainer, and detent stud on the sift spool. Tighten the detent stud to 2.7 to 4.1 Nm.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8005-11

STEP 37

STEP 40

B5803089M Install the detent housing.

B5802489M Lubricate the steel balls and springs with Molykote Type G. Install the steel balls, springs, and plugs.

STEP 38 STEP 41

B5802889M B5802289

Install the lock washers and screws. Do not tighten the screws at this time.

Tighten the plugs to 2.7 to 4.1 Nm.

STEP 39

STEP 42

B5822289M Apply a small amount of 242 Loctite to the threads for the detent.

B5802889M Tighten the screws to 2.7 to 4.1 Nm.

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information

8005-12

STEP 43 If the fittings were removed from the body, make sure the restrictor is installed in the B port of the lift spool. The groove in the restrictor must be in the position shown.

1

3 2

B890695J

1. Restrictor 2. B Port 3. Groove

2

1

3 1 1

7

8

7

4 6 17

18

3 10 15

1

16

14

13 10 11

12 5 1 1 13 1.

2.

3.

4.

5.

O-Ring Plug Spring Poppet Lift Spool

6. Body 7. Backup Ring 8. Main Relief Valve (Remove Cap for Adjustment 9. Detent Housing

3

9

10

1 10.

11.

12.

13.

14.

Spring Retainer Steel Ball Detent Stud Plug Spring Seat

Cross Section of Loader Control Valve

15.

16.

17.

18.

Screw Washer Spring Cap Bucket Spool

8006 Section 8006 AUXILIARY CONTROL VALVE

8006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 6 7

8006-3

SPECIFICATIONS Manufacturer................................................................................................................................ Cessna Fluid Power Spool travel Neutral to pressure..................................................................................................................... 7.9 mm in and out Spool in ...................................................................................................................................... pressure at A port Spool out .................................................................................................................................... pressure at B port Port threads Inlet and outlet................................................................................................. 7/8 inch - 14 straight thread, O-ring A and B ........................................................................................................... 3/4 inch - 16 straight thread, O-ring Special torques Cap screw for centering spring.............................................................................................................. 7 to 11 Nm

8006-4

DISASSEMBLY STEP 1

STEP 3

B313617M

B313619M

Prevent the spool from turning. Loosen and remove the cap screw.

Remove the spring seats, centering spring, and spacer.

STEP 2

STEP 4

B313618M

Push the spool out of the bore approximately 13 mm.

B313621M

Remove the spool.

8006-5

STEP 5

STEP 8

B313620M

Remove the O-ring from the groove at both ends of the bore.

B313626M

Remove the poppet.

STEP 9 STEP 6

B313637M B313624M

Fasten the body in a vise. Loosen and remove the plug.

STEP 7

B313625M

Remove the spring.

Remove the O-ring from the plug.

8006-6

INSPECTION 1. Clean all parts in cleaning solvent.

3. Inspect the spring seats, springs, poppet, and washer for damage or excessive wear. Use new parts as required.

2. Inspect the spool and spool bore in the body for damage or excessive wear. If the spool or the spool bore are damaged or excessively worn a new auxiliary control valve must be used.

2 3

1

4 5 6

3

7

3 10 11

8 9 4 B890697J

1.

2.

3.

4.

LOAD CHECK VALVE PLUG O-RING SPRING

5.

6.

7.

8.

POPPET SPOOL BODY INNER SPRING SEAT

AUXILIARY CONTROL VALVE - EXPLODED VIEW

9. WASHER 10. OUTER SPRING SEAT 11. CAP SCREW

8006-7

ASSEMBLY STEP 10

STEP 13

B313638M

B313624M

Install a new O-ring on the plug.

Install and tighten the plug.

STEP 11

STEP 14

B313628M

Fasten the body in the vise. Install the poppet.

B313629M

Install a new O-ring in the groove in the bore at the spool eye end of the auxiliary control valve.

STEP 12 STEP 15

B313625M

Install the spring.

B313630M

Lubricate the spool and spool bore with clean oil.

8006-8

STEP 16

STEP 19

B313631M

Install the spool. Push the spool into the bore until the O-ring can be installed in the groove in the bore at the spring end of the spool.

B313634M

Apply 242 Loctite to the threads on the cap screw.

STEP 20 STEP 17

B313635M

Install the cap screw.

B313632M

Install a new O-ring in the groove in the bore.

STEP 21 STEP 18

B313636M

Tighten the cap screw to 7 to 11 Nm. B313633M

Use an acceptable tool and install the spring seats, spacer, and centering spring.

8006-9

6

1

10 8

7

11

3

8

12 4

9 10 5

B890698J

1.

2.

3.

4.

LOAD CHECK VALVE BODY SPOOL CAP SCREW

5.

6.

7.

8.

INNER SPRING SEAT PLUG POPPET BODY

AUXILIARY CONTROL VALVE - CROSS SECTIONAL VIEW

9.

10.

11.

12.

OUTER SPRING SEAT SPRING O-RING WASHER

8006-10

NOTES

Section 8007

8007

CYLINDERS

8007-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 3 LOADER LIFT CYLINDER ............................................................................................................................................ 4 Disassembly ........................................................................................................................................................... 4 Inspection ............................................................................................................................................................... 4 Loader Lift Cylinder - Exploded View ......................................................................................................................................... 5 Assembly ................................................................................................................................................................ 6 Loader Lift Cylinder - Cross Section View .................................................................................................................................. 7 LOADER BUCKET CYLINDER ...................................................................................................................................... 8 Disassembly ........................................................................................................................................................... 8 Inspection ............................................................................................................................................................... 8 Loader Bucket Cylinder - Exploded View .................................................................................................................................... 9 Assembly .............................................................................................................................................................. 10 Loader Bucket Cylinder - Cross Section View .......................................................................................................................... 11

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8007-3

SPECIFICATIONS Piston nut torque Loader lift cylinder ................................................................................................................................................. 108 to 136 Nm Loader bucket cylinder ........................................................................................................................................... 122 to 136 Nm

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

8007-4

LOADER LIFT CYLINDER Disassembly

13. Remove the piston (5) from the piston rod (4).

1. Clean the outside of the cylinder.

14. Remove the spacer (9) from the piston rod (4).

2. Fasten the closed end of the cylinder in a vise or other holding equipment. Do not damage the tube (1).

15. Remove the gland (2) from the piston rod (4).

16. Remove the O-ring (10) from the ID of the piston (5).

3. Make an alignment mark on the gland (2) at the slot in the tube (1) so the cylinder can be assembled correctly. Use a marker that does not wash off.

17. Remove the wear rings (11), piston seal (12), and O-ring (13) from the OD of the piston (5).

4. Put the blade of a screwdriver under the lock wire (3) at the gland (2) end of the tube (1).

18. Remove the wiper (14) and wide seal (15) from the ID of the gland (5).

5. There are flats on the outside of the gland (2). Turn the gland (2) to push the lock wire out of the tube (1). Use the screwdriver to guide the lock wire (3) out of the tube (1).

Inspection 1. Discard the parts that were removed from the piston (5) and gland (2).

6. Remove the lock wire (3) from the tube (1).

2. Clean all parts in cleaning solvent.

7. Pull the piston rod (4) straight out of the tube (1) until the piston (5) contacts the gland (2). DO NOT pull the piston rod (4) all the way out of the tube (1).

3. Check to be sure that the piston rod (4) is straight. If the piston rod (4) is not straight, install a new piston rod (4).

8. After the piston (5) contacts the gland (2), slowly pull the piston rod (4) straight out until the O-ring (6) and backup ring (7) are aligned with the slot in the tube (1) for the lock wire (3).

4. Illuminate the inside of the tube (1). Inspect the inside of the tube (1) for deep grooves and other damage. If there is any damage to the tube (1) a new tube (1) must be used.

9. Use an O-ring hook tool to pull the O-ring (6) and backup ring (7) through the slot. Cut and remove the O-ring (6) and backup ring (7).

5. Remove small scratches on the piston rod (4) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion.

10. Pull the piston rod (4) straight out of the tube (1).

11. Fasten a 1 inch (25 mm) diameter steel rod, 8 inches (203 mm) long, in a vise in a vertical position. Install the piston rod eye over the steel rod. Put a support under the piston rod (4) near the piston (5). Put a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4).

12. Loosen and remove the self-locking nut (8) that holds the piston (5).

6. Inspect the gland (2) for rust. Clean and remove the rust as required.

7. Inspect the end of the tube (1) for sharp edges that will cut the O-rings and backup rings. Remove as required.

8. Inspect the piston (5) for damage and wear. If the piston (5) is damaged or worn, a new piston (5) must be used.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8007-5

4

14

2 3 15 6

7

9

10 11 5 13 12 8

11

1

BS96E105

1.

2.

3.

4.

5.

TUBE GLAND LOCK WIRE PISTON ROD PISTON

6.

7.

8.

9.

10.

O-RING BACKUP RING LOCK NUT SPACER O-RING

11.

12.

13.

14.

15.

Loader Lift Cylinder - Exploded View

WEAR RING PISTON SEAL O-RING WIPER WIDE SEAL

Temp ate Date: 1994_04_05

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8007-6

Assembly 1. Install a new wide seal (15) in the ID of the gland (2). The lips of the wide seal (15) must be toward the inside of the cylinder. The wide seal (15) can be difficult to install. Do not damage the wide seal (15).

2. Press a new wiper (14) into the bore of the gland (2). The lips of the wiper (14) must be toward the outside end of the gland (2).

13. Install new wear rings (11) in the grooves at each end of the OD of the piston (5).

14. Lubricate the threaded end of the piston rod (4) with clean oil.

15. Install a new O-ring (10) on the end of the piston rod (4).

Be careful not to damage the O-ring (10).

16. Lubricate the ID of the piston (5) with clean oil.

3. Install a new backup ring (7) in the groove in the OD of the gland (2). If the backup ring (7) is not flat on both sides, the side that is flat must be toward the outside end of the gland (2).

17. Find the end of the piston (5) with the notch for the O-ring (5). The notch for the O-ring must be toward the O-ring (5) on the end of the piston rod (4). Put the piston (5) on the piston rod (4).

4. Install a new O-ring (6) next to the backup ring (7). The Oring must be between the backup rings and the small end of the gland (2).

18. Lubricate the threads in the self-locking nut (8) with clean oil. Install the self-locking nut (8) on the piston rod (4).

Tighten the self-locking nut to 80 to 100 pound-feet (108 to 136 Nm).

5. Fasten the piston rod eye (4) in the vise the same way t h a t t h e p i s t o n r o d eye ( 4 ) wa s fa s t e n e d d u r i n g disassembly.

6. Remove any marks and sharp edges on the chamfer at the end of the piston rod (4). Make sure the piston rod (4) is clean.

7. Lubricate the bore of the gland (2) and the piston rod (4) with clean oil.

8. Push the gland (2) onto the piston rod (4). If necessary, use a soft hammer to drive the gland (2) onto the piston rod (4). The wiper (14) in the gland (2) must be toward the piston rod eye (4).

9. Install the spacer (9) on the piston rod (4).

10. Put a support below and near the end of the piston rod (4). Use a shop cloth between the support and piston rod (4) to prevent damage to the piston rod (4).

19. Lubricate the inside of the tube (1) with clean oil.

Lubricate the wear rings (11) and piston ring (12) with clean oil.

20. Push the piston (4) straight into the tube (1). Use a tool that does not have sharp edges to keep the wear rings (11) and piston ring (12) from coming through the slot in the tube (1).

21. Push the piston (5) straight into the tube (1).

22. When the piston (5) is in the tube (1), carefully start the gland (2) into the tube (1). Use a tool that does not have sharp edges to keep the O-ring (6) and backup ring (7) from coming through the slot in the tube (1).

23. Push the gland (2) into the tube (1) and turn the gland (2) so the mark on the gland (2), made during disassembly, aligns with the slot in the tube (1).

11. Install a new O-ring (13) in the center groove on the OD of the piston (5).

24. Install the new lock wire (3) in the hole in the gland (2).

Turn the gland so that the gland (2) pulls the lock wire (3) into the tube (1), and holds the gland (2).

12. Install a new piston seal (12) over the O-ring (13) on the OD of the piston (5).

25. Hit the end of the lock wire (3) with a hammer to install the end of the lock wire (3) in the slot.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8007-7

1

6

7

15

3

14

4 2 11

8

5

12

9

11

10

13

BT96E106

1.

2.

3.

4.

5.

TUBE GLAND LOCK WIRE PISTON ROD PISTON

6.

7.

8.

9.

10.

O-RING BACKUP RING LOCK NUT SPACER O-RING

11.

12.

13.

14.

15.

WEAR RING PISTON SEAL O-RING WIPER WIDE SEAL

Loader Lift Cylinder - Cross Section View

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

8007-8

LOADER BUCKET CYLINDER Disassembly

13. Remove the piston (5) from the piston rod (4).

1. Clean the outside of the cylinder.

14. Remove the gland (2) from the piston rod (4).

2. Fasten the closed end of the cylinder in a vise or other holding equipment. Do not damage the tube (1).

15. Remove the O-ring (9) from the ID of the piston (5).

3. Make an alignment mark on the gland (2) at the slot in the tube (1) so the cylinder can be assembled correctly. Use a marker that does not wash off.

4. Put the blade of a screwdriver under the lock wire (3) at the gland (2) end of the tube (1).

5. There are flats on the outside of the gland (2). Turn the gland (2) to push the lock wire out of the tube (1). Use the screwdriver to guide the lock wire (3) out of the tube (1).

16. Remove the wear rings (10), piston seal (11), and O-ring (12) from the OD of the piston (5).

17. Remove the wiper (13) and wide seal (14) from the ID of the gland (5).

Inspection 1. Discard the parts that were removed from the piston (5) and gland (2). Discard the lock wire.

2. Clean all parts in cleaning solvent.

6. Remove the lock wire (3) from the tube (1).

7. Pull the piston rod (4) straight out of the tube (1) until the piston (5) contacts the gland (2). DO NOT pull the piston rod (4) all the way out of the tube (1).

8. After the piston (5) contacts the gland (2), slowly pull the piston rod (4) straight out until the O-ring (6) and backup ring (7) are aligned with the slot in the tube (1) for the lock wire (3).

9. Use an O-ring hook tool to pull the O-ring (6) and backup ring (7) through the slot. Cut and remove the O-ring (6) and backup ring (7).

3. Check to be sure that the piston rod (4) is straight. If the piston rod (4) is not straight, install a new piston rod (4).

4. Illuminate the inside of the tube (1). Inspect the inside of the tube (1) for deep grooves and other damage. If there is any damage to the tube (1) a new tube (1) must be used.

5. Remove small scratches on the piston rod (4) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion.

6. Inspect the gland (2) for rust. Clean and remove the rust as required.

10. Pull the piston rod (4) straight out of the tube (1).

11. Fasten a 1 inch (25 mm) diameter steel rod, 8 inches (203 mm) long, is a vise in a vertical position. Install the piston rod eye over the steel rod. Put a support under the piston rod (4) near the piston (5). Put a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4).

12. Loosen and remove the self-locking nut (8) that holds the piston (5).

7. Inspect the end of the tube (1) for sharp edges that will cut the O-rings and backup rings. Remove as required.

8. Inspect the piston (5) for damage and wear. If the piston (5) is damaged or worn, a new piston (5) must be used.

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio 8007-9

4

13 3

14 7 2 6

9 5 10 11 12 10

1

8

BT96E107

1.

2.

3.

4.

5.

TUBE GLAND LOCK WIRE PISTON ROD PISTON

6.

7.

8.

9.

10.

O-RING BACKUP RING LOCK NUT O-RING WEAR RING

11.

12.

13.

14.

Loader Bucket Cylinder - Exploded View

PISTON SEAL O-RING WIPER WIDE SEAL

Temp ate Date: 1994_04_05

A t+ to disp ay temp ate i ormatio

8007-10

Assembly 1. Install a new wide seal (14) in the ID of the gland (2). The lips of the wide seal (14) must be toward the inside of the cylinder. The wide seal (14) can be difficult to install. Do not damage the wide seal (14).

2. Press a new wiper (13) into the bore of the gland (2). The lips of the wiper (13) must be toward the outside end of the gland (2).

13. Install new wear rings (10) in the grooves at each end of the OD of the piston (5).

14. Lubricate the threaded end of the piston rod (4) with clean oil.

15. Install a new O-ring (9) on the end of the piston rod (4).

Be careful not to damage the O-ring (9).

16. Lubricate the ID of the piston (5) with clean oil.

3. Install a new backup ring (7) in the groove in the OD of the gland (2). If the backup rings (7) is not flat on both sides, the side that is flat must be toward the outside end of the gland (2).

17. Find the end of the piston (5) with the notch for the O-ring (5). The notch for the O-ring must be toward the O-ring (5) on the end of the piston rod (4). Put the piston (5) on the piston rod (4).

4. Install a new O-ring (6) next to the backup ring (7). The Oring must be between the backup ring and the small end of the gland (2).

18. Install the self-locking nut (8) on the piston rod (4).

Tighten the self-locking nut to 90 to 100 pound-feet (122 to 136 Nm).

5. Fasten the piston rod eye (4) in the vise the same way t h a t t h e p i s t o n r o d eye ( 4 ) wa s fa s t e n e d d u r i n g disassembly.

19. Lubricate the inside of the tube (1) with clean oil.

Lubricate the wear rings (10) and piston ring (12) with clean oil.

6. Remove any marks and sharp edges on the chamfer at the end of the piston rod (4). Make sure the piston rod (4) is clean.

20. Push the piston (4) straight into the tube (1). Use a tool that does not have sharp edges to keep the wear rings (10) and piston ring (12) from coming through the slot in the tube (1).

7. Lubricate the bore of the gland (2) and the piston rod (4) with clean oil.

21. Push the piston (5) straight into the tube (1).

8. Push the gland (2) onto the piston rod (4). If necessary, use a soft hammer to drive the gland (2) onto the piston rod (4). The wiper (13) in the gland (2) must be toward the piston rod eye (4).

22. When the piston (5) is in the tube (1), carefully start the gland (2) into the tube (1). Use a tool that does not have sharp edges to keep the O-ring (6) and backup ring (7) from coming through the slot in the tube (1).

9. Install the spacer (9) on the piston rod (4).

23. Push the gland (2) into the tube (1) and turn the gland (2) so the mark on the gland (2), made during disassembly, aligns with the slot in the tube (1).

10. Put a support below and near the end of the piston rod (4). Use a shop cloth between the support and piston rod (4) to prevent damage to the piston rod (4).

11. Install a new O-ring (11) in the center groove on the OD of the piston (5).

12. Install a new piston seal (12) over the O-ring (11) on the OD of the piston (5).

24. Install the new lock wire (3) in the hole in the gland (2).

Turn the gland so that the gland (2) pulls the lock wire (3) into the tube (1), and holds the gland (2).

25. Hit the end of the lock wire (3) with a hammer to install the end of the lock wire (3) in the slot.

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1

4

6

7

3 14

13

2

1

8

10

12

11

10 5

9 4

bt96e108

BT96E108

1.

2.

3.

4.

5.

TUBE GLAND LOCK WIRE PISTON ROD PISTON

6.

7.

8.

9.

10.

O-RING BACKUP RING LOCK NUT O-RING WEAR RING

11.

12.

13.

14.

PISTON SEAL O-RING WIPER WIDE SEAL

Loader Bucket Cylinder - Cross Section View

7

9000 Section 9000 PEDALS AND LEVERS

9000-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................... 2 THROTTLE ADJUSTMENT ........................................................................................................................................... 3 PARKING BRAKE ADJUSTMENT .................................................................................................................................. 4 DIRECTION CONTROL LINKAGE ADJUSTMENT ............................................................................................................ 5 LOCK FOR LOADER CONTROL LINKAGE ..................................................................................................................... 7 LOADER CONTROL ADJUSTMENT ................................................................................................................................ 8

SPECIFICATIONS Engine Speeds Low idle ................................................................................................................................................ 1000 to 1100 rpm (r/min) High idle.................................................................................................................................................. 2550 to 2650 rpm (r/min)

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THROTTLE ADJUSTMENT 1. Make sure that the parking brakes are engaged.

2. Disconnect the throttle cable from the wire lock on the arm on the fuel injection pump.

3. Use an accurate photo tachometer to check the engine speeds. Hold the arm on the fuel injection pump in the low idle position to check the low idle speed and in the full throttle position to check the high idle speed. Compare the engine speeds with the specifications on page 2.

4. If the low idle speed is not correct, adjust the low idle stop bolt on the fuel injection pump.

5. If the high idle speed is not correct, the fuel injection pump must be serviced by an authorized service center.

6. When the engine speeds are correct, put the hand throttle in the low idle position. Install the throttle cable in the wire lock on the arm on the fuel injection pump. Hold the arm against the low idle stop bolt while you tighten the wire lock.

7. Put the hand throttle in the full throttle position. The arm on the fuel injection pump must be against the full throttle stop bolt.

1

2

3

BS96C147

1. Hand Throttle

2. Throttle Cable

3. Wire Lock (Connected to Arm on Fuel Injection Pump)

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9000-4

PARKING BRAKE ADJUSTMENT 1. Make sure that the knob on the parking brake switch is all the way down.

3. Lower the seat bars. The seat bar limit switch must be o p e n , a n d t h e b ra ke i n d i c a t o r l a m p mu s t n o t b e illuminated.

2. Raise the seat bars. The arm on the seat bar limit switch must be pushed down enough so that the seat bar limit switch is closed (but not so much that the arm is bent), and the brake indicator lamp must be illuminated. If the seat bar limit switch is not in the correct position and the brake indicator lamp is not illuminated, adjust the ball joint on the left seat bar until the operation is correct.

4. Pull up the knob on the parking brake switch. The brake indicator lamp must be illuminated.

5. If the brake indicator lamp is not illuminated at the correct times, see Section 4002 for troubleshooting procedures.

5

4 2

6

1

5

3

BT96C156

1. Knob on Parking Brake Switch 2. Brake Indicator Lamp

3. Seat Bar Limit Switch 4. Left Seat Bar

5. Ball Joint 6. Right Seat Bar

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DIRECTION CONTROL LINKAGE ADJUSTMENT 1. Raise the machine and use blocks to hold the machine so that the wheels are above the floor.

2. Raise the loader frame and engage the support strut to hold up the loader frame.

6. Check for end play between the spring retainers, the centering spring bracket, and the neutral control rod. If there is end play, loosen the jam nut for the adjusting nut.

Then turn the adjusting nut in or out until there is no end play. When the end play is correct, tighten the jam nut against the adjusting nut.

3. See Section 9003 and tilt the ROPS forward.

4. Find the parking brake rod for the left seat bar.

Disconnect the lower end of the parking brake rod from the spring and the pivot lever. Make sure that nothing is pushing down the arm on the seat bar limit switch. The seat bar limit switch must be open, and the brake indicator lamp must not be illuminated.

5. See the illustration on page 7. Disconnect the shock absorbers from the cross shaft at B and D. Disconnect the neutral control rods from the cross shaft at A and C.

NOTE: If the adjusting nut is too tight, there will be end play between the spring retainers and the centering spring bracket. If the adjusting nut is too loose, there will be end play between the spring retainers and the neutral control rod.

7. Connect the neutral control rods to the cross shaft.

8. Start the engine and run the engine at low idle. If the wheels turn while the direction control levers are in neutral, do the following steps: A. Loosen the jam nuts on the transmission control rods.

B. Disconnect the transmission control rods from the cross shaft.

C. Turn the ball joints to adjust the length of the transmission control rods until the wheels do not turn while the direction control levers are in neutral.

D. Tighten the jam nuts against the ball joints.

9. As a final check, run the engine at high idle. Make final adjustments as necessary.

10. Connect the shock absorbers to the cross shaft.

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9000-6

1

1

4 4 3 2

5

4 6

7

4 5 6 2 3 7

10 8 9

9

10 BS96C182

1.

2.

3.

4.

5.

Direction Control Lever Neutral Control Rod Centering Spring Bracket Spring Retainer Adjusting Nut

6.

7.

8.

9.

10.

Jam Nut for the Adjusting Nut Shock Absorber Cross Shaft Transmission Control Rod Connected to Control Arm on Piston Pump

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LOCK FOR LOADER CONTROL LINKAGE

1

2

4

3

BS96C161

1. Right Seat Bar 2. Adjust Ball Joint As Required So That Lock Plate Does Not Engage Tabs When Seat Bar Is Down

3. Lock Plate 4. Tabs. Align Tabs By Adjusting the Spool Rods Between the Control Valve and the Cross Shaft.

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9000-8

LOADER CONTROL ADJUSTMENT 1

2

1

2

5

3 3

4

BS96C185

1. Control Handle 2. Handle Rod. Adjust Handle Rod So That Control Handle Is at a Good Angle for Operator Comfort and So That Movement of the Control Handle Completely Strokes the Spool in the Control Valve.

3. Tab 4. Lock Plate 5. Spool Rods. Adjust Spool Rods So That Tabs Align With Lock Plate When Spools Are in Neutral.

9002 LOADER

9002

Section

9002-2

TABLE OF CONTENTS REPLACING THE CUTTING EDGE ................................................................................................................................ 3 Weld Specifications for Cutting Edge .......................................................................................................................... 3 REMOVING THE LOADER FRAME ................................................................................................................................ 4 Illustration of Loader Frame ....................................................................................................................................... 5 INSTALLING THE LOADER FRAME ............................................................................................................................... 6 Lift Cylinder Hydraulic Installation ............................................................................................................................... 7 Bucket Cylinder Hydraulic Installation .......................................................................................................................... 8 Illustration of Tool Tach ............................................................................................................................................ 9 Illustration of Pallet Fork ......................................................................................................................................... 10

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REPLACING THE CUTTING EDGE 1. Raise the bucket to an acceptable height and use acceptable supports to hold the bucket in place.

2. Disconnect the wiring from the alternator.

8. When welding the top of the cutting edge to the floor of the bucket, use the following procedure: A. Start at one end of the bucket and weld toward the center until one welding rod has been used.

3. Use carbon arc rod or an acetylene cutting torch to remove the welds that hold the cutting edge. Keep distortion to a minimum amount.

4. When removing the weld at the rear of the cutting edge, do not cut through the bottom of the bucket.

5. Use a grinder to remove any welds or extra metal on the bucket that will prevent the new cutting edge from fitting correctly.

6. Use C-clamps to hold the new cutting edge in position.

B. Start at the center of the bucket and weld in both directions from the center until one welding rod has been used.

C. Start at the other end of the bucket and weld toward the center until one welding rod has been used.

D. Continue to weld using this method until the cutting edge is completely welded to the bucket.

9. Connect the wiring to the alternator.

7. See the weld specifications below.

Weld Specifications for Cutting Edge

3

1

2 1. 4 mm Fillet Weld.

2. Fill Groove at Wear Plate. Then, 5 mm Fillet Weld.

3. 5 mm Fillet Weld. Weld Twice Inside and Outside.

BS96F236

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9002-4

REMOVING THE LOADER FRAME 1. Park the machine on a level surface.

2. Raise the loader frame high enough so that the pivot pins for the rod eyes of the lift cylinders can be driven out in front of the ROPS canopy. Put supports below the loader frame to hold the loader frame in position.

3. Remove the snap ring and the flat washer from the pivot pin for the rod eye of the left-hand lift cylinder. Drive the pivot pin out of the loader frame. DO NOT remove the driver at this time.

4. Remove the snap ring and the flat washer from the pivot pin for the rod eye of the right-hand lift cylinder. Drive the pivot pin out of the loader frame. DO NOT remove the driver at this time.

5. Lower the loader frame so that the bucket is flat on the floor.

6. Hold the right-hand lift cylinder while you remove the driver from the rod eye only. Lower the right-hand lift cylinder out of the way.

10. Clean the connections between the bucket hoses and the bucket tubes near the rear of the right-hand side of the loader frame. Fasten identification tags to the hoses and the tubes.

11. Disconnect the bucket hoses from the bucket tubes.

Install caps on the hoses and plugs in the tubes.

12. If the machine has auxiliary hydraulics, do the following procedure: A. Clean the connections between the auxiliary hoses and the auxiliary tubes near the rear of the left-hand side of the loader frame.

B. Fasten identification tags to the hoses and the tubes.

C. Disconnect the hoses from the tubes. Install caps on the hoses and plugs in the tubes.

13. Connect acceptable lifting equipment to the loader frame.

7. Remove the pin which holds the strut in the stored position. Lower the strut.

14. Remove the self-locking nuts and the bolts from the two pivot pins that fasten the loader frame to the pivot points on the uprights of the machine frame.

8. Remove the driver and the strut.

15. Remove the two pivot pins.

9. Hold the left-hand lift cylinder while you remove the driver. Lower the left-hand lift cylinder out of the way.

16. Raise the loader frame out of the uprights of the machine frame.

17. Carefully move the machine out of the loader frame.

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3

2

5 1

4

1

BS96F237

1. Uprights of Machine Frame 2. Loader Frame

3. Right-Hand Bucket Cylinder 4. Right-Hand Lift Cylinder

Illustration of Loader Frame

5. Strut

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9002-6

INSTALLING THE LOADER FRAME 1. Carefully move the machine into the loader frame.

2. Lower the loader frame into the uprights of the machine frame.

3. Align the holes in the loader frame with the two pivot points on the uprights of the machine frame.

4. Install the two pivot pins that fasten the loader frame to the pivot points on the uprights of the machine frame.

13. Put the loader control in the Float position. Then use a prybar to align the rod eye of the right-hand lift cylinder with the hole in the loader frame.

14. Install the pivot pin through the strut, the rod eye, and the loader frame.

15. Install the flat washer and the snap ring on the outside end of the pivot pin.

16. Start the engine and run the engine at low idle.

5. Install the bolts and the self-locking nuts in the pivot pins.

6. If the machine has auxiliary hydraulics, remove the caps from the auxiliary hoses and the plugs from the auxiliary tubes. Connect the hoses to the tubes.

17. Raise the loader frame high enough so that the pivot pins for the rod eyes of the lift cylinders are in front of the ROPS canopy. Stop the engine. Put supports under the loader frame to hold the loader frame in position.

7. Remove the caps from the bucket hoses and the plugs from the bucket tubes. Connect the hoses to the tubes.

18. Install the flat washers and snap rings on the inside ends of both pivot pins for the rod eyes of the lift cylinders.

8. Disconnect the lifting equipment from the machine.

19. Lubricate all pivot points for the loader frame.

9. Put the loader control in the Float position. Then use a prybar to align the rod eye of the left-hand lift cylinder with the hole in the loader frame.

20. Start the engine and run the engine at low idle.

21. Operate all cylinders through several complete cycles to remove any air from the circuits.

10. Install the pivot pin through the rod eye and the loader frame.

22. Stop the engine and check for oil leaks.

11. Install the flat washer and the snap ring on the outside end of the pivot pin.

23. Check the oil level in the hydraulic reservoir. See Section 1002 for the correct hydraulic oil.

12. Put the strut in position and install the pin which fastens the rear end of the strut to the loader frame.

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BS96F238

Lift Cylinder Hydraulic Installation

Temp ate Date: 1994_04_05

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9002-8

BS96F239

Bucket Cylinder Hydraulic Installation

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BS96F240

Illustration of Tool Tach

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9002-10

BS96F241

Illustration of Pallet Fork

9003 ROPS CANOPY, SEAT BELTS, AND OPERATORS COMPARTMENT

9003

Section

9003-2

TABLE OF CONTENTS ACCIDENT DAMAGE TO ROPS CANOPY ...................................................................................................................... 3 MAINTENANCE AND INSPECTION OF ROPS CANOPY ................................................................................................... 3 ROPS CANOPY INSTALLATION ................................................................................................................................................... 4 SEAT AND SEAT BELT INSTALLATION ........................................................................................................................................ 5 TILTING THE ROPS CANOPY FORWARD ...................................................................................................................... 6 FASTENING THE ROPS CANOPY IN THE OPERATING POSITION ................................................................................... 7 REMOVING THE ROPS CANOPY .................................................................................................................................. 8 INSTALLING THE ROPS CANOPY ................................................................................................................................ 8

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ACCIDENT DAMAGE TO ROPS CANOPY If the machine has rolled over or the ROPS canopy has been in some type of accident (such as hitting an overhead object during transport), you must replace the ROPS canopy to have the same protection you had with the original ROPS canopy.

After the accident check for damage to the ROPS canopy, seat belt, accessories, and wiring in the ROPS canopy.

Before operating the machine, replace all damaged parts.

Do not try to weld or straighten the ROPS canopy.

MAINTENANCE AND INSPECTION OF ROPS CANOPY After every 500 hours of operation or every six months, whichever occurs first, do the following: 1. Check the torque for the mounting bolts for the ROPS canopy. See the illustration on page 4 for torque specifications.

!

WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS serial number plate.

47-26

!

WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way.

DO NOT TRY TO MAKE REPAIRS TO THE ROPS. 47-25

2. Check the torque for the mounting bolts for the seat belts.

See the illustration on page 5 for torque specifications.

3. If a seat belt is damaged in any way, replace the seat belt.

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9003-4

1

2 BS96G001

1. Tighten to 70 to 80 Nm.

2. With ROPS tilted forward and shocks extended, position slide so that spacers are 2.5 mm from the front end of the slot.

ROPS CANOPY INSTALLATION

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1

1

2 BS96G001

1. Tighten to 21 to 24 Nm.

2. Tighten to 70 to 80Nm. SEAT AND SEAT BELT INSTALLATION

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information

9003-6

TILTING THE ROPS CANOPY FORWARD STEP 1

STEP 5

Start and run the engine at idle.

STEP 2 Move the machine forward or backward as required to make sure that the pin in each parking latch engages a hole in the cluster sprocket.

STEP 3

BP96C038 Disconnect the cables from the seat bar locking mechanism on each side.

STEP 6

BP96C016 Raise the loader lift arms to full height. Have another person install the support strut.

STEP 4

BP96C039 Use the grab handles and pull the operators compartment all the way forward.

BP96C055 Loosen and remove the cap screws, lock washers, and flat washers that fasten the ROPS canopy to the posts at the rear of the machine.

Template Name: SM_2_col Template Date: 1994_04_05

Alt= to hide template information Alt+ to display template information 9003-7

FASTENING THE ROPS CANOPY IN THE OPERATING POSITION STEP 1

STEP 4

BP96C030 Use the grab handles and lift the ROPS canopy up and toward the rear of the machine. Carefully lower the ROPS canopy into position.

STEP 2

Install the cap screws, lock washers, and flat washers that fasten the ROPS canopy to the posts at the rear of the machine.

Tighten the cap screws to 70 to 80 Nm.

Connect the cables for the seat bar locking mechanism on each side.

IMPORTANT: The lock plate must be holding the lift and bucket control levers in NEUTRAL.

BP96C055

STEP 3

BP96C038

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9003-8

REMOVING THE ROPS CANOPY STEP 1

STEP 5

See Tilting the ROPS Canopy Forward in this Section and do steps 1 through 6.

Remove the cotter pins and clevis pins that fasten the gas struts to the ROPS canopy.

STEP 2

STEP 6

Disconnect the wiring harness for the ROPS canopy.

Connect acceptable lifting equipment to the ROPS canopy.

STEP 3

STEP 7

Loosen and remove the cap screws, flat washers, and selflocking nuts that fasten the cover for the wiring harness to the frame.

Remove the snap rings from the pivot pins that fasten the front of the ROPS canopy to the machine. Remove the pivot pins.

STEP 4

STEP 8

Pull the wiring harness for the ROPS canopy through the front panel so the wiring harness is free of the machine.

Remove the ROPS canopy from the machine.

INSTALLING THE ROPS CANOPY STEP 1

STEP 5

If the ROPS canopy is being replaced, install the components from the old ROPS canopy on the new ROPS canopy.

Replace all decals as required. Use a piece of soft wire to pull the wiring harness through the conduit in the ROPS canopy.

Remove the lifting equipment from the ROPS canopy.

STEP 2 Lift the ROPS canopy into position and align the front of the ROPS canopy with the machine.

STEP 3 Install the pivot pins and snap rings that fasten the front of the ROPS canopy to the machine.

STEP 4 Connect the gas struts to the ROPS canopy.

STEP 6 Put the wiring harness through the front panel and connect the wiring harness.

STEP 7 Install the cover for the wiring harness. Install the cap screw, flat washers, and self-locking nuts.

STEP 8 See Fastening the ROPS Canopy in the Operating Position in this section and do steps 1 through 4.

Section

AUXILIARY HYDRAULIC INSTALLATION

9004

9004

9004-2

2

F G

F

G

1

BT96D002

1. Loader Control Valve

2. Auxiliary Control Valve

Auxiliary Hydraulic Installation

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY DOCUMENTATION CENTER Strada di Settimo, 323 - S. MAURO T.SE (TO) ITALY

•

Reproduction of text and illustrations, even in part, is strictly prohibited

Print No. 604.13.057.01 July, 2002