Frontier Hydraulic Pump HP2025 HP2134 Operator's Manual(5RDHP2134A3) - PDF DOWNLOAD

Serial # 1XFHP20XCF0150001 and up And 1XFHP21XHF0150021 and up

OM 0399HP-A 04/15

SPECIFICATIONS

OM 0277-A

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TABLE OF CONTENTS SPECIFICATIONS............................................................................................................................................x INTRODUCTION – TO THE PURCHASER ................................................................................................... 3 SAFETY PRECAUTIONS ............................................................................................................................... 4 Before Operation ............................................................................................................................ 4 Notice ............................................................................................................................................. 5 The Hydraulic Pump ...................................................................................................................... 5 Before Operation ............................................................................................................. 5 Hydraulic Pump Operation .............................................................................................. 6 The Tractor .................................................................................................................................... 7 General Information ......................................................................................................... 7 Operating the Tractor ...................................................................................................... 7 During Operation ............................................................................................................. 7 Maintenance .................................................................................................................................. 8 Transport ........................................................................................................................................ 8 Storage ........................................................................................................................................ 8 SAFETY DECALS ..................................................................................................................................... 9-10 ASSEMBLY ............................................................................................................................................... 11-18 Installation of the Hydraulic Pump ............................................................................................... 11 Hydraulic Oil Fill-Up ..................................................................................................... 11 Installation of the Driveline ........................................................................................... 11 Adjusting the Three Point Hitch ................................................................................... 11 Installation of the Quick Couplers ........................................................................... 12-13 Installation of the Hose Supports ............................................................................ 14-15 Installation of the Wiring Harness ........................................................................... 16-18 Installation of the Hydraulic Hoses............................................................................... 19 Installation of the Hydraulic Pump with a Quick Hitch Cat. 1 ....................................... 20 Installation of the Hydraulic Pump with a Quick Hitch Cat. 2 ....................................... 20 Installation of the Hydraulic Pump with a Three Point Hitch Cat. 1 .............................. 21 Installation of the Hydraulic Pump with a Three Point Hitch Cat. 2 .............................. 22 Determining Driveline Length ...................................................................................... 23 Connection the Driveline to the Tractor ....................................................................... 24 Connecting the Hoses and Wiring Harness ................................................................ 25 Installation of the Oil Cooler 5RDF0036 – Option .................................................. 26-27

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TABLE OF CONTENTS OPERATION ................................................................................................................................................ 28-31 Preparation ..................................................................................................................................... 28 Counterweights .............................................................................................................. 28 Operation ........................................................................................................................................ 29 Checking the Oil Temperature ........................................................................................ 29 Checking the Hydraulic Oil Level .................................................................................... 29 Checking Oil Level of the Multiplicator ........................................................................... 29 Removing the Hydraulic Pump ........................................................................................ 30 Reconnecting the Hydraulic pump .................................................................................. 31 MAINTENANCE ................................................................................................................................... 32-40 Lubrication & Periodic Maintenance ................................................................................................ 32 Oil Fill-Up ......................................................................................................................... 33 Oil Change ....................................................................................................................... 33 Replacing the Oil in the Multiplicator................................................................................ 34 Recommended Hydraulic Oil ........................................................................................... 34 Cleaning the Oil Strainer – without an Oil Cooler ............................................................ 35 Cleaning the Oil Strainer – with an Oil Cooler ................................................................. 36 Instruction for Valve Adjustment ...................................................................................... 37 Troubleshooting .......................................................................................................................... 38-39 Electrical Diagram ............................................................................................................................ 40 PARTS ................................................................................................................................................ 41-53 Introduction .......................................................................................................................................... 41 Hydraulic Pump and Tank .............................................................................................................. 42-43 Miscellaneous ................................................................................................................................. 44-45 Hydraulic and Electrical System ...................................................................................................... 46-47 Hose Supports ..................................................................................................................................... 48 Hydraulic Block ................................................................................................................................... 49 Hydraulic Pump .................................................................................................................................... 50 Multiplicator .......................................................................................................................................... 51 Oil Cooler 5RDF0036 - Option ............................................................................................................. 52 Driveline ............................................................................................................................................... 53 TORQUE SPECIFICATION TABLES .................................................................................................. 54-56 OM 0399HP-A

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INTRODUCTION TO THE PURCHASER All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before operation.

Illustrations The illustrations may not necessarily reproduce the full detail and the exact shape of the parts or depict the actual models, but are intended for reference only

This manual has been prepared to assist the owner and operators in the safe operation and suitable maintenance of the implements. The information was applicable to products at the time of manufacture and does not include modifications made afterwards.

Direction Reference Right Hand and Left Hand are determined by those seen by the operator standing behind the equipment.

Read and understand this operator's manual before attempting to put an implement into service. Familiarize yourself with the operating instructions and all the safety recommendations contained in this manual and those labeled on the implements and on the tractor. Follow the safety recommendations and make sure that those with whom you work follow them.

The Dealer is responsible for warranty registration of the unit you have purchased. To assist your dealer in handling your needs, please record hereafter the model number and serial number of your implement and tractor. It is also advisable to supply them to your insurance company. It will be helpful in the event that an implement or tractor is lost or stolen.

MODEL :

SERIAL NUMBER :

DATE OF PURCHASE :

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SAFETY PRECAUTIONS SAFETY FIRST This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit.

DANGER :

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION :

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

IMPORTANT :

Indicates that equipment or property damage could result if instructions are not followed.

NOTE :

Gives helpful information.

All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before operation. It is the owner's responsibility to be certain anyone operating this product reads this manual, and all other applicable manuals, to become familiar with this equipment and all safety precautions. Failure to do so could result in serious personal injury or equipment damage. If you have any questions, consult your dealer.

BEFORE OPERATION Children and Bystanders 4. Never carry children while operating the machine. They may fall off and be seriously injured or interfere with safe operation of the machine.

Tragic accidents can occur if the operator is not alert to the presence of children. Children are generally attracted to machines and the work being done. Never assume children will remain where you last saw them.

5. Never allow children to play on the machine or attachment even when turned off.

1. Keep children out of the operating area and under the watchful eye of another responsible adult.

6. Never allow children to operate the machine even under adult supervision.

7. Use extra care when approaching blind corners, shrubs, trees, or other obstructions that might hide children from sight.

2. Be alert and turn machine off if children enter the work area.

3. Before and when backing, look behind and look for small children.

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SAFETY PRECAUTIONS - continued NOTICE A safe operator is the best insurance against accidents. All operators, no matter how experienced they may be, should read this Operator's Manual and all other related manuals before attempting to operate an implement. Please read the following section and pay particular attention to all safety recommendations contained in this manual and those labeled on the implements and on the tractor.

THE HYDRAULIC PUMP Before Operation 1. Read and understand this operator's manual and tractor operator's manual. Know how to operate all controls and how to stop the unit and disengage the controls quickly.

9. Replace all missing, illegible, or damaged safety and warning decals. See list of decals in the operator's manual.

10. Do not modify or alter this equipment or any of its components or any equipment function without first consulting your dealer.

2. Never wear loose, torn, or bulky clothing around the tractor and implement. It may catch on moving parts or controls, leading to the risk of accident.

11. Keep safety decals clean of dirt and grime.

3. Before the snow season, thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards and other foreign objects.

4. Disengage clutch and shift into neutral before starting the engine.

5. Do not operate equipment in wintertime without wearing adequate winter garments.

6. Never attempt to make any adjustments while engine is running. Read this manual carefully to acquaint yourself with the equipment as well as the tractor operator's manual.

Working with unfamiliar equipment can lead to accidents. Be thoroughly familiar with the controls and proper use of the equipment.

Know how to stop the unit and disengage the controls quickly.

7. Keep all shields in place and properly tighten all mounting hardware.

8. Periodically, inspect all moving parts for wear and replace with authorized service parts if an excessive amount of wear is present.

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SAFETY PRECAUTIONS - continued Hydraulic Pump Operation 1. Before leaving the tractor unattended, take all possible precautions. Disengage the PTO, stop the engine and remove the ignition key. Lower the implement to the ground.

13. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable noises.

2. Before starting the pump, make sure there's sufficient hydraulic oil and that hoses are properly connected.

14. Always keep the "SMV" sign (Slow Moving Vehicle) visible and clean.

15. Make sure the protective nylon sheat is properly installed on the hoses since they contain fluid under pressure and at high heat that can cause injury.

3. Be sure the clutch switch/lever is in OFF position before starting engine.

4. Exercise extreme caution when operating on or crossing a gravel drive, walks, or roads. Stay alert for hidden hazards or traffic.

5. Do not carry passengers.

6. If the pump starts to vibrate abnormally, stop the engine immediately and check for cause. Excessive vibration is generally a sign of trouble.

7. Do not run the engine indoors except when starting engine and transporting attachment in or out of building. Carbon monoxide gas is colorless, odorless and deadly.

8. Exercise extreme caution when changing direction on slopes. Do not attempt to operate on steep slopes.

9. Never operate pump without guards, and other safety protective devices in place.

10. Never operate machine at high transport speeds on a slippery surface.

11. Use extra caution when backing up.

12. Disengage power to the PTO transporting or when not in use.

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SAFETY PRECAUTIONS - continued THE TRACTOR General Information 1. Read the operator's manual carefully before using tractor. Lack of operating knowledge can lead to accidents.

2. Do not allow anyone but the operator to ride on the tractor. There is no safe place for extra riders

Operating the Tractor 1. Never run the tractor engine in a closed building without adequate ventilation, as the exhaust fumes are very dangerous.

14. A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position.

Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with a loader, front wheel weights, ballast in tires, front tractor weights and/or on the power pack. Weigh the tractor and equipment. Do not estimate. Please refer to tractor manual for proper ballasting information.

2. Never allow an open flame near the fuel tank or battery.

3. Make sure the shield is installed when using PTO-driven equipment and always replace the shield if damaged.

4. Always bring the tractor to a complete stop, shut off the engine, lower the implement to the ground and remove the ignition key before leaving the tractor.

5. Never park the tractor on a steep slope.

15. Always make sure all hydraulic pump components are properly installed and securely fastened BEFORE operation.

6. Do not attempt to operate on steep slopes.

During Operation

7. Use of tire chains for better traction and stability is recommended.

1. Do not allow anyone to ride on the tractor/implement at any time. There is no safe place for passengers on this equipment. The operator MUST sit in the tractor seat.

8. Always drive the tractor at speeds compatible with safety, especially when operating over rough ground, crossing ditches, or when turning.

2. Eye and hearing protection is recommended when operating the hydraulic pump.

9. Handle fuel with care, as it is highly flammable.

3. Operate only during daylight hours, or when the area is well lit with bright artificial light.

10. Use approved fuel container.

4. Disengage the PTO (turn to “OFF”), place the transmission in neutral, set the parking brake, shut off the engine and remove the key, and make sure rotating components have stopped BEFORE leaving the operator’s seat.

11. Never add fuel to a running engine or a hot engine.

12. Fill fuel tank outdoors with extreme care.

Never fill fuel tank indoors. Replace fuel cap securely and wipe up spilled fuel.

5. Inspect the hydraulic pump after striking any foreign object to assure that all implement parts are safe and secure and not damaged.

13. Never allow anyone to operate the front mount implement until they are thoroughly familiar with basic tractor and implement operation.

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SAFETY PRECAUTIONS - continued MAINTENANCE

TRANSPORTATION

1. Park the tractor/hydraulic pump on level ground, set the parking brake, disengage the PTO, shut off the engine, remove the key, and lower the implement to the ground BEFORE making any hydraulic pump adjustments.

1. If the tractor/hydraulic pump is to be driven on public roads, it must be equipped with an SMV (Slow Moving Vehicle) sign.

Check local traffic codes that may apply to unit usage on public roads and highways in your area.

2. Keep the tractor/hydraulic pump clean.

Snow and ice build-up can lead to malfunction or personal injury from thawing and refreezing in garage.

2. Be alert for all other traffic when driving the tractor/ hydraulic pump on public roads or highways.

3. During transport, the hydraulic pump must be in the raised position.

3. Always wear eye protection when cleaning or servicing the hydraulic pump.

4. Do not work under any part of the tractor or hydraulic pump, unless it is securely supported by safety stands.

STORAGE 1. Before storing the hydraulic pump, certain precautions should be taken to protect it from deterioration.

5. Make sure all shields and guards are securely in place following all service, cleaning, or repair work.

2. Clean the hydraulic pump thoroughly.

6. Do not modify or alter this equipment or any of its components or operating functions. If you have questions concerning modifications, consult with your dealer.

3. Make all the necessary repairs.

4. Replace all Safety Signs that are damaged, lost, or otherwise become illegible. If a part to be replaced has a sign on it, obtain a new safety sign from your dealer and install it in the same place as on the removed part.

7. Even when stopped, the hydraulic pump (hoses, oil tank, and pump) can contain fluids under pressure and at high heat. To release the pressure, switch off the tractor.

If the pressure persists, contact your dealer. Be very careful when performing maintenance on this equipment.

5. Repaint all parts from which paint has worn or peeled.

6. Lubricate the hydraulic pump as instructed under "Lubrication" section.

7. When the hydraulic pump is dry, oil all moving parts. Apply oil liberally to all surfaces to protect against rust.

8. Place the dust caps on the hoses. Store the hydraulic hoses in the hose support on top of the oil tank and secure in place with the connector support and the hairpins.

9. Attach the driveline to the pump with the chain provided with the pump.

10. Store in a dry place

.

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DECALS Replace immediately if damaged

5RD2500796

5RD2500791

5RD2500795

5RD2500794

5RD2500798

5RD2500829

5RD2500793 OM 0399HP-A

5RD2500797 9

5RD2500792

DECALS Replace immediately if damaged

5RD2500868

5RD2500785

5RD655834 5RD2500822

5RD2500786

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5RD2500821

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ASSEMBLY INSTALLATION OF THE THREE POINT HYDRAULIC PUMP The hydraulic pump is assembled at the factory; however it needs to be installed and connected. Use the present manual and lay out all parts. Separate bolts and nuts into various sizes. After installation, torque all the bolts and the hydraulic fittings according to the "Torque Specification Tables" at the end of the manual.

Hydraulic Oil Fill-Up The hydraulic pump is delivered without hydraulic oil. Fill up the oil tank according to the instructions in the "Maintenance" section.

Installation of the Driveline Figure 1: Remove the two M12 x 1.25 x 70 bolts (item 4) and the nylon insert locknuts (item 5).

Connect the driveline (item 2) to the pump's driveshaft (item 1). Attach with the two M12 x 1.25 x 70 bolts (item 4) and the nylon insert locknuts (item 5). Maintain in place with the chain (item 3).

WARNING: To avoid serious personal injuries: If the collar is not locked to the shaft at tractor end and the bolts not well tighten to the pump shaft (a "click" must be heard), the driveline can fly loose with great force capable of causing serious injury or death.

Figure 1

NOTE: To better illustrate the installation of the pump on the tractor, figures 20 and up do not show the driveline.

4

Adjusting the 3 Point Hitch Figure 2: Adjust the three point hitch at maximum height by screwing the right arm adjustable link to its maximum using the handle (item 1).

For the left arm, remove the linchpin (item 2) and remove the adjustable link (item 3) from the upper anchoring point (item 4). Screw the adjustable link (item 3) to the maximum and reinstall. Make sure the two lower arms are at the same height.

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1 Figure 2

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ASSEMBLY Installation of the Quick Couplers Tractor Legend: 3X20 = 3320, 3520, 3720 4X20 = 4120, 4320, 4520, 4720 3R = 3033R, 3039R, 3046R 4R = 4044R, 4052R, 4066R

3X20 & 3R TRACTOR

Front support - fig.3 1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the middle hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. Install two 3/4"NPT x 1/2"NPT male adaptors (item 6) followed by a 1/2" male quick coupler, a 1/2" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

Rear support - fig.4 & 5 1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the rear hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

Figure 3

Figure 4

2. Install two 3/4"NPT x 1/2"NPT male adaptors (item 6) followed by a 1/2" male quick coupler, a 1/2" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

NOTE: Refer to figure 5 for the position of the quick couplers.

Figure 5

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ASSEMBLY 4X20 & 4R TRACTOR

Front support – figure 6 1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the middle hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. With thread sealant, install a 3/4" male quick coupler and a 3/4" female quick coupler (item 4) with their respective dust plug and dust cap (item 5).

Rear support – figures 7 & 8 1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the rear hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. With thread sealant, install a 3/4" male quick coupler, a 3/4" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

Figure 6

Figure 7

NOTE: Refer to figure 8 for the position of the quick couplers.

Figure 8

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ASSEMBLY Installation of the Hose Supports NOTE: Refer to the parts section on page 48 to identify the hose supports and to figure 9a for their exact location on the loader arm.

1. Figure 9: Attach the rear hose support (item 1) and the fastening bracket (item 2) to the left front loader arm (item 3) with two 5/16" NC x 1 1/4" lg bolts, 5/16" flat washers and 5/16" NC nylon insert nuts (items 4-14-5).

2. Figure 9: Attach the middle hose support (item 7) and its fastening bracket (item 6) with one 5/16"NC x 1 1/4" lg. bolts and one 5/16"NC nylon insert nuts (items 8-9), by inserting it in one of the two support slots according to the loader arm thickness (detail B).

3. Figures 9: Attach the lower part of the front hose support (item 10) and its fastening plate (item 11) with one 5/16"NC x 3 1/2" lg bolts and one 5/16" NC nylon insert nuts (items 12-13) and the upper part with 1/4"NC x 6" flattened bolt, a bushing and a 1/4"NC nut (items 15-16-17).

CAUTION: Do not cover the loader arm decals particularly with the front support (items 1011).

IMPORTANT - Detail A: Make sure the flattened portion of the 1/4"NC bolt faces the loader cylinder and is in a position that ensures the cylinder doesn't interfere with the bolt.

Figure 9 Figure 9a

4. A- For 3X20 & 3R – tractors - fig.10a: Attach the hose support in the same location as the tractor hose support located under the left tractor step plate using the existing tractor bolt.

Install the round wire lock pin in the support as shown.

On some tractor, it may be necessary to position the support with an angle as shown on fig.10a.

B- For 4X20 & 4R – tractors - fig.10: Attach the hose support (item 1) on the front loader support plate located under the step plate (item 2) with a 5/8"NC x 2" lg bolt (item 3) and a 5/8"NC nylon insert nut (not illustrated). Install the round wire lock pin (item 4) in the holes of the support.

3

4

2 Figure 10

Figure 10a

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1

ASSEMBLY 5. Run the hydraulic hoses from the rear of the tractor to the front without inserting them in the hose supports. The straight hose fittings go on the front of the tractor.

Figure 11

6. Figures 11: Connect the hoses (item 2) to the rear bulkhead adaptors (item 1).

7. A- Without cab: Figure 12: Remove the bolt and the flat washer that holds the left fender to the tractor frame.

2 1

Insert a M10 x 1.5 x 60mm bolt (not illustrated) in the hole of the bent section of the fastening bracket (item 1).

Insert the fastening bracket, from the front to the rear, around the tractor post (item 2) and secure with a M10 x 1.5 x 60mm bolt for the 4X20& 4R or a M10 x 1.5 x 40mm bolt for the 3X20 & 3R (item 3), and the tractor flat washer previously removed, located between the bracket and the tractor aisle. DO NOT use this flat washer for the 3X20 & 3R tractor.

After installing the hoses on the bulk head adaptors, attach the rear hose support (item 4) around the tractor post inserting the front part first and secure in place with a 3/8" flat washer (not illustrated) and a 10mm nylon insert nut (not illustrated).

Figure 12

5

4

Attach the rear section with a 10mm nylon insert nut (item 5).

6

B- With cab: Figure 12A: 3X20: 9"

Attach the rear hose support (item 1) and it's fastening bracket (item 2) to the tractor post (item 3) at about 9" from the axle's upper plate for the 3X20 & 3R series and at 6 3/4" for the 4X20 & 4R series with two M10 x 1.5 x 60mm bolt, 3/8" flat washers and two 10mm nylon insert nut (items 4-56).

4X20: 6 ¾"

2 1

3 Figure 12A OM 0399HP-A

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ASSEMBLY Installation of the Wiring Harness TRACTORS: 3X20, 4X20, 3R without cab and 4R without cab 1. Figure 13: Connect the red wire terminal (item 1) of the harness with the fuse holder, to the battery's positive terminal (item 2) and the black wire terminal (item 3) to the battery's negative terminal (item 4).

Attach the harness to the tractor wiring close to the relay with a tie wrap (item 5).

2. Figures 14-15: Insert the wiring harness (item 1) in the rubber boot (item 2). On some tractor models it may be necessary to remove the hose clamp (item 3) to be able to insert the harness. Reinstall the clamp once the harness is installed.

5

4

3

Figure 13

1

2

Figure 15

2

1

3

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Figure 14

3. Figure 15: Run the wiring harness (item 1) along the front of the tractor frame and attach to the tractor wiring or hoses (item 4) with tie wraps. Run the harness close to the hose support located under the step plate (not illustrated).

1

2

16

4

ASSEMBLY 4. Figure 16: Find the tractor's drive wheel activation switch on the transmission near the left rear axle (item 1), accessible from the bottom of the left footstep. Disconnect the 2 cavity connector.

Connect the identical harness connector to the activation switch and the tractor's 2 cavity connector to the wiring harness.

5. Figure 17: Run the harness all the way to the back making sure not to interfere with the movement of the tractor levers and keeping as far away as possible from the wheel.

Bring the harness to the rear hose support (item 1) and tie the harness close to it so the connector (item 2) is at the same level as the quick couplers previously installed. Tie the harness to all the critical areas on the tractor.

1

Figure 16

NOTE: Attach the surplus of the harness in a place far from the wheels and the tractor control levers in movement.

2

1

Figure 16a

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ASSEMBLY 3R & 4R TRACTORS with cab 1. Figure 17: Remove the protective cover of the battery located under the right step.

Connect the red wire terminal (item 1) of the harness with the fuse holder, to the battery's positive terminal (item 2) and the black wire terminal (item 3) to the battery's negative terminal (item 4).

Attach the harness to the tractor wiring close to the relay with a tie wrap (item 5).

2. Place the harness under the cab, above the transmission to reach the activation switch of the drive wheels near the left rear axle, between the two oil filters.

3. Figures 17a-17b: Assemble the two 5 1/2" adapter harnesses (fig.17a) to the main harness.

Disconnect the two cavities connector (Fig.17b).

Connect the same harness connector to the activation switch, and then connect the tractor connector previously removed, to the electrical harness.

4. Figure 17c: Fasten the harness with nylon tie wraps along its path between the cab and the transmission. Wrap the harness excess length and fasten with nylon tie wraps above the battery.

5. Replace the protective cover of the battery.

6. Complete the installation with step 5 on the previous page.

1

3

2

4

5

Figure 17

Fig. 17b

Fig. 17c

Fig. 17a

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ASSEMBLY Installation of the Hydraulic Hoses 1. Figure 18: Connect the hoses to the front bulkhead adaptors (item 1). Hoses should not be inserted in the supports to make it easier to connect the hoses in the front. Tighten the lower hose first (item 2).

2. Figure 19a: Insert the hoses (item 1) in the rear hose support (item 2) of the left loader arm.

3. Figures 19b-19c: Run the hoses (item 1) under the tractor as shown on figure 19b then insert the hoses in the hose support located under the step plate (item 2) then lock in place with a round wire lock pin (item 3).

Figure 18

Figure 19a

2

1

1

Figure 19b

2

Figure 19c

1 2

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3

ASSEMBLY Installation of the Hydraulic Pump with a Quick Hitch Cat. 1 Figure 20: Place the hydraulic pump (item 1) on flat hard ground. Unlock the lower locks of the quick hitch (item 2).

Back up the tractor slowly aligning the three quick hitch hooks (item 4) with the three bushings (item 3) of the hydraulic pump and lock the quick hitch lower locks.

Installation of the Hydraulic Pump with a Quick Hitch Cat. 2 1. Figure 21: Remove the linchpins (item 1), lockwashers (item 3), nuts (item 2) and pins (item 4). Use a round stalk to block the cat.1 and 2 pin during the loosening and the tightening of the nut.

Figure 20

2. Figure 22: Install the pins (item 1) in the position illustrated and reinstall the lockwashers (item 3), nuts (item 2), and linchpins (item 4).

3. Figure 23: Place the hydraulic pump (item 1) on flat hard ground. Unlock the lower locks of the quick hitch (item 2).

Back up the tractor slowly aligning the three quick hitch hooks (item 4) with the three bushings (item 3) of the hydraulic pump and lock the quick hitch lower locks.

Figure 21

Figure 22

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Figure 23 20

ASSEMBLY Installation of the Hydraulic Pump with a Three Point Hitch Cat. 1 1. Figure 24: Remove the linchpins (item 1), nuts (item 2), lockwashers (item 3) and pins (item 4). Remove the hairpin (item 5), pin (item 6) and bushing (item 7). The lower quick hitch bushings (item 8) can remain in place.

Figure 24

2. Figure 25: Insert the pins (item 1) in the position illustrated.

Reinstall the lockwashers (item 3), the nuts (item 2) and the linchpins (item 4).

Figure 25

3. Figure 26 Insert the two pins (item 1) in the lower links (item 2) and lock in place with linchpins (item 3). Attach the upper link (item 5) with the 4" lg. pin (item 4) and lock in place with the hairpin (item 6).

Figure 26

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ASSEMBLY Installation of the Hydraulic Pump with a Three Point Hitch Cat.2 1. Figure 27: Remove the linchpins (item 1), nuts (item 2), lockwashers (item 3) and pins (item 4). Remove the hairpin (item 5), pin (item 6) and bushing (item 7). Remove the spring pins (item 8) and the bushings (item 9).

Figure 27

2. Figure 28: Insert the pins (item 1) in the position illustrated. Reinstall the nuts (item 2), lockwashers (item 3) and the linchpins (item 4).

Figure 28

3. Figure 29: Insert the two pins (item 1) in the lower links (item 2) and lock in place with linchpins (item 3). Attach the upper link (item 7) by inserting a cat.1 & cat.2 bushing (item 5, sold separately #5RD4600056), the 4" pin (item 4) and a hairpin (item 6).

Figure 29

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ASSEMBLY Determining Driveline Length

Figure 30

IMPORTANT: To not damage the equipment, it is essential that the driveline is not too long. At working position, the two half drivelines must intersect each other sufficiently to insure maximum efficiency but there must not be any interference.

1. To determine the "L" length for your tractor model first find the "X" factor by measuring the distance between the end of the tractor's drive shaft and the end of the hydraulic pump's driven shaft when the hydraulic pump is in raised position as shown on Figure 30.

2. Deduct 4" from the "X" length measured from the tractor to obtain the "L" length from center to center of the journal crosses:

L = X – 4" 3. Hold the two half-shaft side by side and locate the "L" length between the two center-to-center half-shaft universal joints.

Mark off the zone to be cut on both halves opposite each half-shaft guard as shown on Figure 31.

Figure 31

4. Cut off inner and outer guard tubes as well as the inner and outer telescopic sections.

5. Cut the guard a second time leaving the same distance between the end of the guard and the end of the shaft as existed before.

To obtain the proper distance "A" shown on Figure 32, cut the guard according to the following table:

Figure 32

DISTANCE A Male Driveline

Female Driveline

1 3/4"

1 1/4"

6. File down tubes and remove chips.

7. Apply grease to inside of outer telescopic section.

A WARNING: To avoid serious personal injuries that may cause death, work with fully guarded shafts only.

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23

ASSEMBLY Connecting the Driveline to the Tractor Figures 33a-33b: Release the springhook (item 1) to remove the chain (item 2) from around the driveline (item 3) and reattach the springhook in its original position (item 1).

Connect the driveline (item 4) to the tractor driveshaft (item 5).

Attach each driveline chains (item 6) to the tractor lower hitches (item 7) to prevent the guards from spinning.

Figure 33a

Figure 33b

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24

ASSEMBLY Connecting the Hydraulic Hoses and Wiring Harness

1. Figure 34: Remove the hoses (item 2) from the hose support (item 1) on the hydraulic pump.

2. Figure 35: Connect the hoses to the rear tractor ports (item 1).

3. Figure 35: Connect the wiring harness to the rear tractor connector (item 2).

Figure 34

2

1 Figure 35

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25

ASSEMBLY Installation of the Oil Cooler 5RDF0036 - Option 1. Figure 36: Unscrew the 1 1/16" JIC elbow (item 1) from the in-tank filter. Remove the 3/4"NC x 2" lg bolt (item 2) and the stover nut (item 3). Remove the stover nut (item 4) from the 3/4"NC x 4 1/2" lg bolt but do not remove the bolt.

Figure 36

2. Figure 36a: Unscrew the straight 1-1/16"JIC adapter (item 1) and rotate the hose of 90° up to bring up the 90° 1-1/16"JIC elbow adapter (item 2). Tighten the straight 11/16"JIC adapter, to rotate the hose, at 65-75 ft-lb (93-101 N-M).

3. Figure 37: Install the oil cooler support (item 1) with a 3/4" NC x 2" lg bolt (item 2) and the 3/4" stover nut (item 3) removed previously. Reinstall the 3/4" NC stover nut (item 4) previously removed on the 3/4" NC x 4 1/2" bolt.

Figure 36a

4. Figure 38: Install the support plates (item 1) with six 5/16" NC x 1" bolts (item 2), eight 5/16" flat washers (item 3) and six 5/16" NC nylon insert nuts (item 4) making sure to place a flat washer between the support plates and the "U" section of the frame.

Figure 38

OM 0399HP-A

Figure 37

26

ASSEMBLY 5. Figure 39: Install the rubber bushings (items 1-2) on the support then attach the oil cooler (item 3) with four 5/16" NC x 2 1/4" bolts (item 4), 5/16" flat washers (item 5), the flat washers supplied with the rubber bushings (item 6) and 5/16" NC nylon insert nuts (item 7). IMPORTANT: Position the oil cooler so the by-pass valve (item 8) faces the rear as illustrated.

Figure 39

6. Figure 40: Install the 1 5/8" ORB – 1 1/16" JIC elbows (item 1) on the oil cooler's inlet and outlet in the positions illustrated. Connect the straight end of the outlet hose (item 2) to the oil cooler elbow and the bent end to the filter. Connect the inlet hose (item 3) previously disconnected from the filter to the other elbow making sure it passes outside the support plate (item 4).

7. Figure 41: Connect the oil cooler fan harness (item 1) to the available connector on the hydraulic pump's wiring harness (item 2).

Figure 40 Figure 41

1

2

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27

OPERATION PREPARATION 1. Figure 42: Raise the three point hitch at maximum making sure the adjustable arms are at maximum height. (see section "Adjusting the Three Point Hitch". When the pump is fully raised, the driveline must be at an angle nearest to 5º with the ground. If not, adjust the three point hitch until the driveline has the correct angle to prevent premature wear of the driveline. The angle of the pump's input shaft is also very important; it must be as parallel as possible with the output shaft of the tractor.

2. Raise the parking stands and lock in place with the wire lock pins.

IMPORTANT: If the three point hitch is not adjusted correctly and the parking stands are not raised, ground clearance and the pump's angle will be affected making it more difficult to travel on uneven terrain.

3. Before starting the tractor, make sure the oil level of the oil tank and multiplicator is correct (see sections "Checking the Hydraulic Oil Level" and "Checking Oil Level of the Multiplicator".

4. Attach a suitable implement to the tractor front loader making sure the implement is compatible with the hydraulic pump (see specifications for each).

5. For equipment other than the snowblower, working in warm region, use the 5RDF0036 oil cooler.

IMPORTANT: To not damage the oil cooler, it is essential to disconnect the fan of the oil cooler when the temperature is under 0°C. 6. Figure 43: The new HP2025 and HP2134 pumps are equipped with a safety system to prevent the hydraulic oil from overheating.

When the hydraulic block is not power supplied, the oil is in recirculation mode meaning that the equipment will not function. To power the block, the ignition key must be in the "ON" (1) or "START" (2) position. If the system remains in the recirculation mode, refer to the "Troubleshooting" section at page 38.

7. Engage the tractor PTO. Run the equipment 2 to 3 minutes to make the hydraulic oil circulate throughout the system. Disengage the PTO and check the oil level in the oil tank once more. Add oil if needed.

OM 0399HP-A

Figure 42

Figure 43

1

2 Without Cab

|

With Cab

Counterweights IMPORTANT: Make sure the tractor has counterweights as recommended by the dealer. Weights provide the necessary balance to improve stability, traction and steering. The recommended Quick Tatch weights are available at your local John Deere dealer.

Figure 44: Remove the counterweight rods (item 1) and the hairpins (item 2). Hang the counterweights (item 3) on each side of the hydraulic pump. Reinstall the rods (item 1) and the hairpins (item 2).

Figure 44

28

OPERATION Checking the Oil Temperature Figure 45: Check the oil temperature indicated on the thermometer (item 1) of the hydraulic pump (item 2).

IMPORTANT: The oil temperature must never exceed 149ºF (65ºC). If the temperature is above that, disengage the hydraulic pump to allow the oil to return to a temperature below 149ºF (65ºC). A temperature higher than 149ºF (65ºC) could cause damage to the hydraulic components.

Checking the Hydraulic Oil Level Figure 46: The oil level must be between the red line and blue line of the level indicator (item 1). If the level is close to the red line, add some oil to bring it back to the blue line. Make sure the oil level never goes below the red line on the indicator (item1).

Figure 45

IMPORTANT: Make sure the oil level never goes below the red line on the indicator while in operation or it could cause damage to the hydraulic pump.

Checking Oil Level of the Multiplicator Figure 46: To check the oil level, simply look through the oil level plug (item 1) located on the right hand side of the multiplicator. If the gauge glass is yellowish, the oil level is good. If it's white, add someSAE80W90 oil.

Figure 46

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29

OPERATION Removing the Hydraulic Pump 1. Figure 47: Remove the wire lock pins (item 2), lower the parking stands (item 1) and lock in place with the wire lock pins (item 2). Lower the hydraulic pump to the ground.

IMPORTANT: The pump must be lowered on level ground since the hydraulic pump has a high center of gravity and could tip over if it's set on uneven ground.

2. Figure 48: Disconnect the hoses (item 1) and the harness (item 2) if they are connected to the tractor and install the appropriate dust caps/plugs on each hose connector and tractor outlets.

NOTE: The contact of the tractor must be cut to remove the pressure in the system. If the pressure persists, contact your dealer.

Figure 47

3. Figure 49: Place the hoses and wiring harness on top of the hydraulic pump.

Insert the hoses (item 2) in the hose support (item 1).

2

4. Figure 47: Disconnect the driveline (item 3) from the tractor's driveshaft (item 4).

5. Figure 42: Attach the driveline (item 3) to the hydraulic pump with the chain (item 4).

Figure 48

Figure 49 OM 0399HP-A

30

1

OPERATION 6. A - For Quick Hitch Installation: Figure 50: Unlock the lower locks of the quick hitch. Lower the three point hitch to release the hooks (item 1) from the pump's attaching points (item 2) and move the tractor forward slowly.

B - For Three Point Hitch Installation: Figure 51: Remove the hairpin (item 6) and the pin (item 4) to release the upper link (item 5) and place it on its support (not illustrated). Remove the linchpins (item 3) to release the lower links (item 2) from the pins (item 1) and move the tractor forward slowly.

Figure 50

Reconnecting the Hydraulic Pump 1. Adjust the three point hitch according to the instructions on page 11.

2. Install the hydraulic pump on the tractor according to the instructions starting on page 20: - With quick hitch Cat. 1 – page 20 - With quick hitch Cat. 2 – page 20 - With 3 point hitch Cat. 1 – page 21 - With 3 point hitch Cat. 2 – page 22 3. Attach the driveline according instructions on page 24.

to

the

4. Install the hydraulic hoses according to the instructions on page 25.

5. Proceed with the operating procedures on page 28.

Figure 51

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31

MAINTENANCE LUBRICATION & PERIODIC MAINTENANCE Periodic maintenance is essential for top performance. Use the Table below as a guide for normal periodic maintenance.

Keep a log of the maintenance performed and the hours run. Recording maintenance will help you keep it regular and provide a basis for supporting warranty claims.

BREAK IN – After first 24 hours After first 100 hours 8 hours (DAILY) 400 hours or annually PROCEDURE X

X

X

COMMENTS

Check all hardware for proper tightness

Tighten appropriately

Check for oil leaks

Tighten the fittings that are leaking

X

X

Change hydraulic oil

Change more often if the machine operated at hi temperatures.

X

X

Change hydraulic oil filter

Change more often if machine operates in dusty and/or hot conditions

X

Clean hydraulic strainer

X

Change the oil of the multiplicator

Use SAE80W90 oil

X

General inspection

Check for oil leaks, loose parts, unusual noises or vibrations

X

Check hydraulic oil level

Add oil if needed

X

Grease and oil driveline

Grease each journal cross. Separate the sliding parts and cover each one of them with grease. Oil the connections.

oil

tank Perform more often when operating in dusty and/or hot conditions

Monthly: Check oil level of the multiplicator and add gear oil SAE80W90 if needed.

OIL CAPACITY Type Hydraulic oil (oil tank only) Hydraulic oil (complete hydraulic system without oil cooler Hydraulic oil (complete hydraulic system with oil cooler Gear oil (multiplicator)

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32

QTY (Liter/gallon) 57 / 15 68 / 18 72 / 19 0.8 / 0.2

MAINTENANCE NOTE: The hydraulic pump can remain attached to the tractor for oil fill ups and oil changes; just make sure the pump is level.

Oil Fill-Up - Figure 52 1. Remove the cap from the filter container (item 2), the spring (item 3) and the filter (item 4). Fill up the oil tank up to the blue line of the level indicator (item 5) through the filter container (item 6) (refer to the following page for the oil to use). Reinstall the filter, the spring and the cap (items 2-3-4).

2. Reinstall the hydraulic pump and run the equipment installed on the front loader 2 to 3 minutes.

Readjust the oil level so it reaches the blue line of the level indicator if needed.

WARNING: Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing severe injuries.

•

1. Hydraulic line 2. Cardboard 3. Magnifying glass

•

Shut engine off and relieve pressure before connecting or disconnecting lines.

•

Tighten all connections before starting engine or pressurizing lines.

•

If any fluid is injected into the skin, obtain medical attention immediately or gangrene may result.

Oil Change - Figure 52 1. Remove the plug (item 1) under the oil tank and let it drain completely.

2. Reinstall the plug (item 1).

3. Remove the cap from the filter container (item 2), the spring (item 3) and the filter (item 4). Fill up the oil tank up to the blue line of the level indicator (item 5) through the filter container (item 6) (refer to the following page for the oil to use).

Do not use your hands to check for leaks.

Use a piece of cardboard or paper to search for leaks.

Figure 52 6.

4. Install a new filter (item 4) (part number 5RD3900493). Reinstall the spring and the cap (items 3-2).

5. Reinstall the hydraulic pump and run the equipment installed on the front loader 2 to 3 minutes.

Readjust the oil level so it reaches the blue line of the level indicator if needed. .

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33

MAINTENANCE Replacing the Oil in the Multiplicator (Figure 53)

Figure 53

1. Remove the oil plug (item 1) under the multiplicator and let it drain completely.

Clean the plug if it's a magnetic plug.

2. Reinstall the plug (item 1).

3. Remove the breather (item 2) on top of the multiplicator. Add 0.85 quart (0.8 liter) of oil SAE 80W90. Check through the oil level plug (item 3) if there's enough oil. Add oil as needed until it reaches the proper level.

Reinstall the breather (item 2).

Recommended Hydraulic Oil 1. Always use superior quality hydraulic oil.

The recommended brands are: John Deere : Low viscosity, Hy-Gard 32, Hy-Gard 68; Shell : Tellus 22-32-46-68, Tellus T 22-3246-68 and Formula 10W40; Esso : Mobil DTE 10M series 12M-13M15M-16M and Extra 10W40; Petro Canada : Hydrex AW 22-32-46-68, Hydrex MV 22-36-60 and Supreme 10W40; Chevron : ECO hydraulic ISO 32-46-68, AW hydraulic ISO 22-32-46-68 and Supreme 10W40; Irving : Hydraulic AW 22-32-46-68, Hydraulic LP 22-32-46-68 and Velco 10W40;

3. Never store oil with the intention of reusing it. Always use new oil when making an oil change.

4. When using hydraulic oil in the hydraulic system, always empty the oil tank completely to eliminate the water that can accumulate on the bottom.

5. When using 10W40 oil in the hydraulic system, always do an oil change in the spring and in the fall without taking into consideration the number of hours showing in order to eliminate water that might emulsify in the oil.

6. If the machine is not being operated or is in operation less than 200 hours a year, replace the hydraulic oil at least once a year except if using 10W40 oil when it must be changed in the spring and in the fall.

2. The viscosity of the oil to use is determined by the outdoor temperature when the machine is in use.

Oil Selection Chart Grade 10W40 Grade 68 Grade 46 Grade 32 Grade 22 -22F(-30C)

-4F(-20C)

14F(-10C)

32F(0C)

Temperature OM 0399HP-A

34

50F(10C)

68F(20C)

86F(30C)

MAINTENANCE Cleaning the Oil Strainer – without an oil cooler 1. Figure 54 Remove the pump from the tractor (see section "Removing the Hydraulic Pump" and place it on level ground.

Remove the plug (item 1) under the oil tank and let it drain completely.

2. Figure 54: Unscrew the 1 1/16" JIC elbow (item 2) on the hydraulic bloc and the 1 1/16" JIC straight fitting (item 3) close to the pump.

WARNING: There should still be oil in the system and it will drain when the pump hose is removed. Once the oil is completely drained, remove the hose between the pump and the hydraulic block.

3. Figure 54: Unscrew the 1 1/16" JIC straight fitting (item 4) on the hydraulic block. This hose can remain in place when removing the tank.

4. Figure 55: Remove the flat bar (item 5) by taking off the four bolts and nuts (items 1-23-4) as well as the spacer rings and shim (items 6-7).

5. Figure 55: Remove the six bolts and nuts (items 8-9-10-11).

6. Figure 55: Loosen the upper collar (item 12) of the suction hose.

7. Figure 56: Lift the tank (item 1) and unscrew the strainer assembly (item 2). Inspect thoroughly for any damage and replace if necessary otherwise clean it. Put thread sealant and reinstall the strainer.

NOTE: Use thread sealant "Permatex anaerobic seal kit #51813" over the male parts. If this product is not available, use at least 4 thicknesses of nylon thread sealant over each male part.

8. Reassemble the hydraulic pump by reversing the previous steps.

Figure 54

Figure 55

Figure 56 OM 0399HP-A

35

MAINTENANCE Cleaning the Oil Strainer – with an oil cooler 1. Figure 54: Remove the pump from the tractor (see section "Removing the Hydraulic Pump" and place it on level ground. Remove the plug (item 1) under the oil tank and let it drain completely.

2. Figure 57: Remove the nut and bolt (items 1-2) then, without removing it, slightly loosen the nut of the support plate (item 3) to allow movement of the support.

3. Figure 58: Remove the nut (item 1) then partially remove the bolt (item 2) to free the oil cooler support. Without removing it, slightly loosen the nut of the support plate (item 3) to allow movement of the support. Unscrew the 1 1/16" JIC elbow (item 4) from the filter.

Figure 57

4. Figure 59: Flip the oil cooler (item 1) 90° towards the outside and unscrew the 1 1/16" JIC fitting (item 2).

Continue with steps 2 to 7 of the section "without oil cooler".

5. Reassemble the hydraulic pump by reversing the previous steps.

Figure 58

Figure 59 OM 0399HP-A

36

MAINTENANCE Pressure Valve Adjustment – with or without oil cooler PRESSURE GAUGE INSTALLATION 1. Figure 60: Remove the 7/16"ORB plug (item 1) and insert a pressure gauge in that port. If the pressure gauge doesn't fit, install a 1/4" hose between the port and the gauge.

PRESSURE SETTING 2. Figure 60: Locate the relief valve (item 3) on the hydraulic pump located near the pump under the hydraulic tank. To have access to the adjustment screw, remove the plug (item 4). Engage the PTO and run the tractor engine at 1800 rpm.

Check the pressure on gauge: -

2700+/-100 psi for HP2025 3000+/-100 psi for HP2134.

If not, adjust pressure by turning the screw in the valve. (Screwing will increase pressure and unscrewing will decrease pressure). After the adjustment, reinstall the plug (item 4).

ATTENTION: The valve plug must be securely installed while the pump is in operation.

Figure 60

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37

MAINTENANCE TROUBLESHOOTING WARNING: Several corrective measures present a certain risk, which may cause serious injuries or death.

WARNING: Hot engine parts and hydraulic oil can cause serious burns.

Always let the engine cool before proceeding with repairs or maintenance.

Only a qualified person, familiar with the risks associated with hydraulics, electricity and machinery should perform the repairs. Review the safety precautions at the beginning of this manual.

IMPORTANT: The oil temperature must never go above 65ºC (149ºF) to avoid damages to the hydraulic components.

The following chart serves as a guide in case of a malfunction. If the problem is not solved after taking the appropriate corrective measure, contact your dealer.

PROBLEM • • • • • 1. The front mount equipment • isn't working • • • •

• • 2. The front mount equipment • is working at low speed • (low hydraulic flow) •

OM 0399HP-A

CORRECTIVE MEASURE Check that the PTO is engaged.

Check that the hoses are connected correctly.

Check hydraulic pump oil level and add some if needed.

Check that the oil temperature is not too high.

Check that the hydraulic block is receiving electrical current. If not, refer to item #5.

Check for oil leaks.

Check that solenoid valve is working properly and replace if needed.

Check that temperature gauge is working properly and replace if needed.

Check that the pump is working properly and replace if necessary.

Check that the multiplicator is working properly and replace if necessary Check engine RPM and increase as needed.

Check hydraulic pump oil level and add some if needed.

Check for oil leaks.

Check the viscosity of the hydraulic oil.

Check the front mount equipment. Refer to the Operator's manual of the equipment.

38

MAINTENANCE

PROBLEM

CORRECTIVE MEASURE

• 3. The front mount equipment is working but in reverse.

•

Check that the pressure hose is connected to the letter "P" on the hydraulic blocks of the pump and the equipment.

Check the connections of the equipment. Refer to the Operator's manual of the equipment.

• • • • 4. The front mount equipment • is working with low power • (low hydraulic pressure) •

Check the oil level of the hydraulic pump.

Check the viscosity of the hydraulic oil.

Check if the tractor engine is at full RPM Check for oil leaks.

Check the filter. Clean or replace if needed.

Check the strainer. Clean or replace if needed.

Check the adjustment of the pressure valve. Adjust if necessary. (see page 37).

Check the front mount equipment. Refer to the Operator's manual of the equipment.

Check that the pump is working properly and replace if necessary.

• •

5. There is no electric signal on the hydraulic block.

OM 0399HP-A

• • • • • • •

Check the connections between the hydraulic pump and the tractor.

Check the position of the ignition key (see page 28).

Check the fuse on the wiring harness.

Check the battery connections.

Check the connection on the tractor connector.

Check the relays.

Check the connections on the solenoid valve: o solenoid valve: red on 1, purple on 2 o Temperature gauge: purple on 1, black on 2

39

MAINTENANCE ELECTRICAL DIAGRAM

OM 0399HP-A

40

PARTS INTRODUCTION All parts are illustrated in "exploded views" which show the individual parts in their normal relationship to each other. Reference numbers are used in the illustrations. These numbers correspond to those in the "Reference Number" (REF) column, and are followed by the description and quantity required.

O/L - "Obtain Locally" in the part number column indicates common hardware that is available at your local hardware supply.

Right Hand and Left Hand are determined by those seen by the conductor standing behind the equipment.

The manufacturer reserves the rights to change, modify, or eliminate from time to time, for technical or other reasons, certain or all data, specifications, or the product or products themselves, without any liability or obligation.

The parts listed here are available through your local dealer.

MANUAL HOLDER REF. 1 2 3

DESCRIPTION Manual holder Bolt hex. 5/16" NC x 1" lg gr. 5, PTD Nut nylon insert 5/16" NC, PTD

OM 0399HP-A

QTY 1 2 2

41

PART # 5RD4200030 O/L O/L

PARTS HYDRAULIC PUMP & TANK

OM 0399HP-A

42

PARTS HYDRAULIC PUMP & TANK REF. DESCRIPTION Hardware bag (not illustrated)

- for HP2025 - for HP2134

1 2 3 4 5

Hydraulic tank Adaptor 2" NPT-hose 3 15/32" lg Hose 2" x 3" lg Hose 1" x 5" lg (for Donaldson filter ONLY) Pump & multiplicator ass'y - for HP2025 - for HP2134 6 - Multiplicator 3.4:1 (incl. in 5RD3910024 or 5RD3910061) 7 - Pump 32cc/rev 2.5PB (incl. in 5RD3910061) - for HP2025 - Pump 40cc/rev 3PB (incl. in 5RD3910024) - for HP2134 - Coupling for hydraulic pump 5RD3910026 (incl. in 5RD3910024) 8 Or for hydraulic pump 5RD3910079 (incl. In 5RD3910061) 9 Temperature and oil level gage - Seal kit for 5RD3900464 - Repair kit for 5RD3900464 (including seal and screw) 10 Strainer 50 GPM with 3 psi bypass 11 In-tank filter 31 GPM with 25 psi bypass including element -Replacement element for 5RD3900451 (Donaldson) -Replacement element for 5RD3900492 (Sofima) 12 Air breather (for Donaldson filter ONLY) 12A Air breather (for Sofima filter ONLY) 13 O-ring 0.118" x 1.475" 14 Adaptor 1 5/8" ORB - 2 hoses 15 Collar, stainless 3/4" to 1 3/4" for hose ( ) 16 Collar, stainless 2.32" to 2.48" for hose 17 Hex. bolt 3/8 NC x 1" gr.5, PTD 18 Allen socket head cap screw 3/8" NC x 1 1/2", PTD 19 Hex. bolt 3/8 NC x 3 1/2" gr.5, PTD 20 Hex. bolt M12 x 1.75 x 25mm lg gr.8.8 PTD 21 Hex. bolt M10 x 1.50 x 40mm lg, gr. 8.8 PTD 22 Plug 3/8" NPT 23 Nylon insert locknut 3/8" NC PTD 24 Lockwasher 3/8", PTD 25 Lockwasher 10mm, PTD 26 Lockwasher 12mm, PTD 27 Seal kit for filter 5RD3900451 (for Donaldson filter ONLY) 27A Seal kit for filter 5RD3900492 (for Sofima filter ONLY) 28 Filter Box Cover (Sofima) 29 Air breather Cover (Sofima) OM 0399HP-A

43

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 4 4 4 1 6 2 4 4 1 1 1 1

PART # 5RD669531 5RD669492 5RD669167 5RD669207 5RD669208 5RD669212 5RD3910061 5RD3910024 5RD3910027 5RD3910079 5RD3910026 5RD3910029 5RD3900464 5RD3900465 5RD3900466 5RD3900449 5RD3900492 5RD3900456 5RD3900493 5RD3900452 5RD3900496 5RD3900454 5RD2600198 5RD2600209 5RD4200035 O/L O/L O/L O/L O/L 5RD654068 O/L O/L O/L O/L 5RD3900468 5RD3900498 5RD3900499 5RD3900497

PARTS MISCELLANEOUS

OM 0399HP-A

44

PARTS MISCELLANEOUS REF. 1

DESCRIPTION

QTY

Hyd. pump/tank support

1

P ART # 5RD669485

2

Parking stand

2

5RD669168

3

Upper link

1

5RD669501

4

Counterweight rod

2

5RD669170

5

Shim 3/8", 2 holes PTD

1

5RD669172

6

Spacer ring .81int. dia x 1 15/32" lg x 1 1/4" ext. PTD

2

5RD669173

7

Chain 35" lg. with springhook

1

5RD669210

8

Bushing 1 1/4 " ext. x 2-13/32" lg x .770" int. PTD

1

5RD669211

9

Bushing 1.135" int. x 1 1/2" ext. x 2 15/16" lg

2

5RD668379

10

Driveline series 40 28" c/c closing

1

5RD4700159

11

SMV reflective sign

1

5RD4200029

12

Hex. bolt 1/4" NC x 1" gr.5, PTD

2

O/L

13

Hex. bolt 3/4" NC x 2" gr.5, PTD

2

O/L

14

Hex. bolt 3/4" NC x 4 1/2" gr.5, PTD

2

O/L

15

Nylon insert locknut 1/4" NC, PTD

2

O/L

16

Stover lock nut 3/4 NC, PTD

4

O/L

17

Flat washer 1/4" (5/16 int), PTD

2

18

Spring pin 3/8" x 1 1/2", black

2

O/L 5RD1600022

19

Hairpin 4mm x 80mm, PTD

2

5RD1800002

20

Hairpin 3mm x 65mm, PTD

1

5RD1800004

21

Linchpin 7/16", PTD

2

5RD1900003

22

Square wire lock pin 3/8" x 2 1/2"

2

5RD1900008

23

Hitch pin cat. 1 & 2, PTD

2

5RD654204

24

Pin 3/4" x 4", PTD

1

5RD665009

25

Protective rubber 1" lg.

2

5RD669348

OM 0399HP-A

45

PARTS HYDRAULIC & ELECTRICAL SYSTEMS

OM 0399HP-A

46

PARTS HYDRAULIC & ELECTRICAL SYSTEMS REF. DESCRIPTION 1 Hydraulic hose ø3/4" x 38"

QTY 2

PART # 5RDHP2025 5RD3700184

PART # 5RDHP2134 5RD3700184

2

Hydraulic hose ø3/4" x 30 1/2"

1

5RD3700158

5RD3700158

3

Hydraulic hose ø3/4" x 53 1/2"

1

5RD3700180

5RD3700180

4

Hose guard

1

5RD669152

5RD669152

5

Hydraulic block

1

5RD3920033

5RD3920037

6

Hex. bolt ø1/4"NC x 2 3/4" gr.5 PTD

2

O/L

O/L

7

Nylon insert nut ø1/4"NC PTD

2

8

Fitting ø7/8"ORB x 1 1/16"JIC

4

O/L 5RD2600058

O/L 5RD2600058

9

Elbow 90° ø1 1/16"JIC M x 1 5/16"ORB M

2

5RD2600204

5RD2600204

10 Wiring harness

1

5RD4000085

5RD4000085

11 Dust plug

3

5RD2600133

5RD2600196

12 Female quick coupler ø1/2"NPT

3

5RD662702

---

Female quick coupler ø3/4"NPT

3

---

5RD661294

13 Dust cap

3

5RD664898

5RD2600197

14 Male quick coupler ø1/2"NPT

3

5RD2600092

---

Male quick coupler ø3/4"NPT

3

---

5RD661293

15 Adaptor 1/2"NPT male x 3/4"NPT fem

6

5RD2600217

16 Bulkhead adaptor ø1 1/16"JIC M x 3/4"NPT M

4

5RD2600221

5RD2600221

17 Bulkhead nut ø1 1/16"JIC

4

5RD2600165

5RD2600165

18 Hydraulic hose ø3/4" x 120"

2

5RD3700182

---

Hydraulic hose ø3/4" x 134"

2

---

5RD3700183

19 Protective nylon sheeting

1

5RD669536

5RD669534

20 Wiring harness for hydraulic pump

1

5RD4000084

5RD4000084

21 Fuse 40A ATO

1

5RD4000087

5RD4000087

22 Relay 12V

2

5RD4000028

5RD4000028

23 Female wiring harness 5.5" lg (for 3R & 4R series)

1

5RD4000133

5RD4000133

24 Male wiring harness 5.5" lg (for 3R & 4R series)

1

5RD4000134

5RD4000134

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PARTS HOSE SUPPORTS REF.

DESCRIPTION

QTY

P ART #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Hose support/front loader Fastening plate - front hose support Middle hose support Fastening bracket - middle hose support Rear hose support Fastening bracket - rear hose support Hose support - tractor rear Fastening bracket - tractor rear hose support Hose support - tractor front Hex. bolt 5/16" NC x 1 1/4" gr. 5, PTD Hex. bolt 5/16" NC x 3 1/2" gr. 5, PTD Hex. bolt 5/8" NC x 2" gr. 5, PTD Nylon insert locknut 5/16" NC, PTD Nylon insert locknut 5/8" NC, PTD Hairpin 2.5mm x 40mm Round wire lock pin 1/4" x 1 3/4" Spacer ring 2 3/8" lg, PTD Chain 1/8" & pin, PTD Chain 1/8" x 3 11/32", PTD Cotter pin 5/32" x 3/4", PTD Bolt 1/4"NC x 6" flattened Nylon insert nut 1/4", PTD Flat washer 5/16" (3/8" hole), PTD Bolt M10 x 1.5 x 60mm full thread Flat washer 1/4" (5/16" hole), PTD Nylon insert nut 10mm, PTD Bolt M10 x 1.5 x 40mm

1 1 1 1 1 1 1 1 1 3 1 1 4 1 1 1 1 1 1 2 1 1 2 2 1 2 1

5RD671263 5RD671260 5RD671257 5RD671258 5RD669521 5RD669522 5RD669532 5RD669566 5RD669523 O/L O/L O/L O/L O/L 5RD1800001 5RD1900006 5RD669518 5RD669513 5RD669514 5RD1500005 5RD669516 O/L O/L O/L O/L O/L O/L

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PARTS HYDRAULIC BLOCK REF. DESCRIPTION 1 Cartridge 2 way, 2 positions

QTY 1

5RD3920039

- Seal kit for 5RD3920039

1

5RD3920041

2

Coil 12VDC DIN connector for 5RD3920039

1

5RD3920040

3

Relief valve preset at 3000 PSI for HP2134

1

5RD3920025

Relief valve preset at 2700 PSI for HP2025

1

5RD3920038

- Seal kit for 5RD39200025 and 5RD3920038

1

5RD3920032

4

Fitting 7/8"ORB M x 1 1/16"JIC M

4

5RD2600058

5

Temperature switch 210°F

1

5RD3920042

6

Hydraulic plug 7/16"ORB M Allen head

2

5RD2600213

7

DIN connector

2

5RD4000062

8

Hydraulic plug 9/16"ORB M

1

5RD2600212

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PARTS HYDRAULIC PUMP REF. DESCRIPTION Complete seal kit (incl. #1 to 5) 1 -Shaft seals 2 -Washer 3 -Retaining ring 4 -Bushing seals and anti-extrusion 5 -Housing seals 6 Bolt kit (including #7) 7 -Reference pin 8 Bushings (incl. #9 for HP2134) 9 -Plate 10 Drive gear 11 Driven gear 12 Drive & driven gears 13 Flange 14 Housing 15 Cover 16 Key & nut

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QTY 1

P ART # HP2134 HP2025 5RD3910026 5RD3910079 5RD3910050 5RD3910080

1

5RD3910051

5RD3910081

1

5RD3910053

5RD3910083 N/A

1 1 1 1 1 1

5RD3910054 5RD3910055

-----

---

5RD3910084 5RD3910082 5RD3910085 5RD3910086 5RD3910087

5RD3910052 5RD3910056 5RD3910057 5RD3910087

PARTS MUTIPLICATOR REF. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

DESCRIPTION Body carter Filler breather plug Washer Level gauge 3/8" BSP plug Gasket Shaft seal 50mm x 65mm x 8mm Bearing 50mm x 80mm x 16mm Seeger Key PTO shaft Crown Bearing 45mm x 75mm x 16mm Pinion Shaft seal 45mm x 60mm x 7mm Body cover Pin D=5 Screw M8x28 Magnetic plug 3/8" BSP (not shown)

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51

P ART # 5RD3910031 5RD3910032 5RD3910033 5RD3910034 5RD3910035 5RD3910036 5RD3910037 5RD3910038 5RD3910039 5RD3910040 5RD3910041 5RD3910042 5RD3910043 5RD3910044 5RD3910045 5RD3910046 5RD3910047 5RD3910048 5RD3910049

PARTS OIL COOLER - 5RDF0036 REF. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DESCRIPTION Oil cooler with by-pass valve and fan 12V - Bolt and seal kit (incl.in 5RD3900474) - Hydraulic plug kit (incl.in 5RD3900474) - By-pass valve kit (incl.in 5RD3900474) - Fan 12V ass. (incl.in 5RD3900474) Oil cooler support Plate for oil cooler support Hydraulic hose 3/4" x 30 1/2" lg Elbow 90° 1 5/8"ORB M x 1 1/16"JIC M Bushing for vibration damping Hex. bolt 3/4"NC x 2 1/4" gr5, PTD Hex. bolt 5/16"NC x 2 1/4" gr5, PTD Hex. bolt 5/16"NC x 1" gr5, PTD Flat washer 5/16" (3/8" hole), PTD Nylon insert nut 5/16"NC, PTD

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QTY 1 1 1 1 1 1 2 1 2 4 1 4 6 16 10

P ART # 5RD3900474 5RD3900475 5RD3900476 5RD3900477 5RD669620 5RD669510 5RD669540 5RD3700158 5RD2600218 5RD4200043 O/L O/L O/L O/L O/L

PARTS DRIVELINE 5RD4700159 REF. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

DESCRIPTION Yoke ass'y Journal cross Yoke for female tube Female tube Male tube Yoke for male tube Yoke ass'y Bolt M12 x 1.25 x 70 with nut Grease fitting Ball Ø1/4" Shear bolt 8mm x 1.25 x 50 gr.8.8 and nut Protector and chain Pin for outer tube Pin for inner tube

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QTY 1 2 1 1 1 1 1 2 1 23 1 1 1 1

P ART # 5RD660764 5RD660765 5RD663189 5RD4700160 5RD4700161 5RD663193 5RD4700058 5RD662199 5RD663129 5RD663163 5RD4700060 5RD4700164 5RD4700061 5RD4700062

TORQUE SPECIFICATION TABLE

GENERAL SPECIFICATION TABLE USE THE FOLLOWING TORQUES WHEN SPECIAL TORQUES ARE NOT GIVEN Note:These values apply fasteners as received from supplier dry, or when lubricated with normal engine oil. They do not apply if special graphited or moly sidulphide greases or other extreme pressure lubricants are used. These values apply to dry conditions; under lubricated conditions reduce by 25% the torques in this table.

BOLT HEAD IDENTIFICATION INCHES

METRIC

Bolt Size

Bolt Size Grade 2

Grade 5

Grade 8

1 2

5.8

8.8

10.9

Class 5.8

Class 8.8

Class 10.9

in-tpi =

3 4

*Torque tolerance +0%, -15% of torquing values. Unless otherwise specified use torque values listed above

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ADAPTER INSTALLATION PROCESS NPT THREAD IDENTIFICATION & TORQUE D in

mm

Identification of adapter

0.375 0.500 0.625 0.780 0.988 1.236 1.583 1.823

9.5 12.5 15.9 19.8 25.1 31.4 40.2 46.3

1/8 NPT 1/4 NPT 3/8 NPT 1/2 NPT 3/4 NPT 1 NPT 1 1/4 NPT 1 1/2 NPT

Number of turns to do after manual tightening

2.0 - 3.0 2.0 - 3.0 2.0 - 3.0 2.0 - 3.0 2.0 - 3.0 1.5 - 2.5 1.5 - 2.5 1.5 - 2.5

RECOMMENDED ASSEMBLY The method used to assemble fittings with NPT threads is done in two stages. First firmly tighten by hand then tighten once again according to the number of turns listed in the above table. The following steps are recommended to minimize the risks of leaks and/or damages to the parts.

STEP 1: Inspect threads and tapping to make sure they are clean.

STEP 2: Measure the diameter (D) of the adapter and take note of the size taken.

STEP 3: Apply a sealant/lubricant product to the NPT threads (teflon covered threads are preferable to other lubricating products). If PTFE tape (teflon) is used, make between 1.5 or 2 turns clockwise, when viewed by the fitting end, keeping free the two first threads.

CAUTION: More than 2 turns can cause distortion or cracks in the orifice.

STEP 4: Tighten the fitting manually.

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STEP 5: Screw the fitting the number of turns listed on the above table making sure that in the case of an elbow fitting the end is aligned to the desired position to connect the tube or hose. Never unscrew a fitting to obtain the proper alignment.

STEP 6: If a leak is detected after having followed the preceding instructions, check that the threads are not damaged and the number of seated threads is fulfilled (see details in next paragraph).

If the threads are much damaged, replace the fitting. If the tapping is damaged, retap if possible or replace the part.

Usually, the number of threads seated is between 3.5 and 6. If the range is different it would indicate that the fitting was tightened too much or not enough or that the tightening was not within thread tolerances. If the fitting is not tight enough, tighten but never more than one turn. If it's too tight, control the threading and tapping and replace the section that has threads that are not within tolerances.

ADAPTER INSTALLATION PROCESS JIC THREAD IDENTIFICATION & TORQUE D in

mm

Identification of adapter

0.433 0.496 0.559 0.740 0.870 1.055 1.185 1.307 1.618 1.870 2.492

11 12.6 14.2 18.8 22.1 26.8 30.1 33.2 41.1 47.5 63.3

5/16 JIC 3/8 JIC 7/16 JIC 1/2 JIC 9/16 JIC 3/4 JIC 7/8 JIC 1 1/16 JIC 1 3/16 JIC 1 5/16 JIC 1 5/8 JIC 1 7/8 JIC 2 1/2 JIC

TORQUE lbs-ft N-m 6-7 6-9 9-12 14-15 18-20 27-39 36-63 65-88 75-103 85-113 115-133 125-167 190-258

8-10 8-12 12-16 19-21 24-27 37-53 49-85 88-119 102-140 115-153 156-180 169-226 258-350

JIC flare fittings seal with metal to metal contact between the flared nose of the fitting and the flared tube face in the female connection.

The minimum torque values listed are to provide a benchmark that give optimum results for leak free connections. Actual torque values should be based on individual application.

NOTE: Do not apply thread sealant (teflon tape) on the JIC threads.

Leaks can result from vibration, thermal cycling and from loads being supported by the connection (i.e. using the fitting in the connection to support mechanical loads).

IMPORTANT: Use the lowest torque value from the chart when wet torquing.

RECOMMENDED ASSEMBLY

ALTERNATE ASSEMBLY METHOD

STEP 1: Inspect for possible contamination or damage from shipping or handling. Sealing surface should be smooth.

STEP 1: Inspect for possible contamination or damage from shipping or handling. Sealing surface should be smooth.

STEP 2: Lubricate the threads and the entire surface of the cone with hydraulic fluid or a light lubricant.

STEP 2: Lubricate the threads and the entire surface of the cone with hydraulic fluid or a light lubricant.

STEP 3: Align mating components for hand connection and turn flare nut until sealing surfaces make full contact.

STEP 3: Align mating components for hand connection and turn flare nut until sealing surfaces make full contact.

STEP 4: Torque nut to the values shown in the above table. If a wrench pad is provided nest to nut, place a second wrench on pad to prevent flare from rotating while being torqued.

STEP 4: Lightly wrench tighten the nut until there is firm resistance.

STEP 5: When torquing nut onto a straight flared fitting, it may be necessary to also place a wrench on the flared fitting wrench pad to prevent it from turning during assembly.

STEP 6: Place second wrench on nut as near the 3 o'clock position as possible.

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STEP 5: Place a wrench on wrench pad next to nut as near the 6 o'clock position as possible.

STEP 7: Turn nut clockwise to no less than the 4 o'clock position, but no more than the 6 o'clock position. Required rotation generally decreases as size increases.

ADAPTER INSTALLATION PROCESS ORB (O-RING BOSS) THREAD IDENTIFICATION & TORQUE in

D mm

Identification of adapter

TORQUE N-m lbs-ft

0.433 0.496 0.559 0.740 0.870 1.055 1.185 1.307 1.618 1.870 2.492

11 12.6 14.2 18.8 22.1 26.8 30.1 33.2 41.1 47.5 63.3

3/8 ORB 7/16 ORB 1/2 ORB 9/16 ORB 3/4 ORB 7/8 ORB 1 1/16 ORB 1 3/16 ORB 1 5/16 ORB 1 5/8 ORB 1 7/8 ORB 2 1/2 ORB

8-9 13-15 14-15 23-24 40-43 43-48 68-75 83-90 112-123 146-161 154-170 218-240

12-13 18-20 19-21 32-33 55-57 59-64 93-101 113-122 152-166 198-218 209-230 296-325

SAE O-rings (O-Ring Boss) are straight thread fittings that seal using a O-ring between the thread and the wrench flats of the fitting. The O-ring seals against the machined seat on the female port.

O-ring fittings can be either adjustable or non-adjustable. Non adjustable fittings are screwed into a port where no alignment is needed. Adjustable fittings can be oriented in a specific direction.

Fittings with O-rings offer advantages over metal-to-metal fittings. Under or over-tightening any fitting can allow leakage, but all-metal fittings are more susceptible to leakage because they must be tightened to a higher and narrower torque range. This makes it easier to strip threads or crack or distort fitting components, which prevents proper sealing.

NOTE: Do not apply thread sealant (teflon tape) on the ORB threads.

Leaks can also result from vibration, thermal cycling and from loads being supported by the connection (i.e. using the fitting in the connection to support mechanical loads).

IMPORTANT: Use the lowest torque value from the chart when wet torquing.

RECOMMENDED ASSEMBLY ORB (O-R ING ) NONADJUSTABLE STEP 1: Inspect all components damage or contamination.

RECOMMENDED ASSEMBLY ORB (O-R ING ) ADJUSTABLE STEP 1: Inspect contamination. for

STEP 2: Lubricate O-ring and threads on fitting with your hydraulic sytems fluid.

all

components

for

damage

or

STEP 2: Lubricate O-ring and threads on fitting with your hydraulic sytems fluid.

STEP 3: Looking at fitting from the male ORB end, turn manually the nut as far as possible from the O-ring.

STEP 3: Turn fitting into port until finger tight, then torque to the value shown in the following table.

STEP 4: Using wrench, turn fitting into port until the washer touches thread nearest wrench pad.

NOTE: Use the lowest torque value from the chart when wet torquing.

STEP 5: Back off fitting counterclockwise not exceeding one revolution until it is oriented in the correct position.

STEP 6 : Place wrench on the wrench pad of fitting to prevent fitting from turning, and torque nut to the value shown in the following table.

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PART NO. 5RDHP2134A3

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