Volvo Mc80b Skid Steer Loader Service Manual

Service Information Document Title: Hydraulic system contamination

Function Group: oil 900

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic system oil contamination Microscopic Contamination Microscopic contamination occurs when excessive fine particles of foreign material are in the system oil. These particulates are too small to see or feel.

Examples of contamination problems caused by excessive particulates would include the following:   

cylinder rod seals leak, control valve spools do not return to neutral, and/or hydraulic circuit has a high operating temperature.

Sense Contamination Sense contamination is foreign matter found by sight, touch or smell. This type of contamination can cause a sudden failure of a hydraulic component. Examples of sense contamination are:     

particles of metal or dirt in the system oil, air in the system oil, system oil dark and thick, odor of burned system oil, and/or water in the system oil. Water will cause oil to become white in color.

Service Information Document Title: Function Group: Working hydraulic system, 900 description

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Working hydraulic system, description The circuit contains an implement pump that pulls system fluid from the hydraulic tank and delivers it to the lift and tilt cylinders and the auxiliary function via a three-spool main control valve assembly with an open center.

For more detailed information, see 990 Hydraulic diagram and forward.

Service Information Document Title: Hydraulic oil, description

Function Group: 900

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic oil, description The machine is standard-equipped with mineral-based hydraulic oil and bio–oil is available as an option.

The hydraulic oil contains selected additives that give good oxidation stability, good corrosion protection and good lubricating characteristics.

Service Information Document Title: Function Group: Hydraulic oil, storing and 900 handling

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic oil, storing and handling    

Hydraulic oil should be stored in tightly sealed tanks or barrels.

Only containers intended for transport of hydraulic oil may be used for this purpose.

Hydraulic oil should be stored indoors or in temperature-controlled facilities. If hydraulic oil is stored outdoors, the barrels should be stored horizontally to prevent penetration of water and eradication of barrel markings.

In order to avoid condensation, oil should not be stored in temperatures above 60 °C (140 °F), or be exposed to intense sunshine or cold temperatures.

Service Information Document Title: Function Group: Hydraulic components, 900 cleanliness when handling

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic components, cleanliness when handling WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

NOTICE It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and may lead to expensive downtime. Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil.

NOTE! A vacuum pump should be used for work on the hydraulic system in order to avoid oil spills.

Service Information Document Title: Function Group: Hydraulic system, repair of 900 hydraulic components in workshop

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic system, repair of hydraulic components in workshop  

      

Always wear clean coveralls and maintain strict personal cleanliness.

Work with hydraulic components should be performed separate from other work in the shop, in a so-called "clean room". The room should have good ventilation and the floor should be coated with a binding material. Machining, grinding, etc. must not be performed in the "clean room".

The workplace should be equipped with thoroughly cleaned tools and suitable containers for cleaning hydraulic components.

Containers used for cleaning hydraulic components must not be used for other cleaning. The containers should be cleaned often and filled with new fluid.

Clean all components that are going to be handled in the "clean room". Do not use caustic soda solutions or similar, which will result in corrosion.

Always plan work on the hydraulic system so that it can be completed without long interruptions.

When cleaning during repairs – use dry and clean compressed air for drying, not rags.

When work is completed, always plug components with clean plastic plugs of suitable dimensions and package them.

When cleaning the "clean room" – use methods that do not stir up dust and dirt.

Service Information Document Title: Function Group: Hydraulic components, 900 storage and transport

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic components, storage and transport   

All hydraulic components should be stored in plastic bags or plastic foil and they should be plugged. The packaging must not be opened until the component is to be used.

Service vehicles should be equipped with an interior which facilitates good order and cleanliness.

Each service vehicle should have a roll of plastic foil, plastic plugs of the most common dimensions and plastic containers for components. Plugs and foil should be of the disposable type, that is, for one-time use only.

Service Information Document Title: Function Group: Connecting/disconnecting 900 vacuum pump instructions

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Connecting/disconnecting vacuum pump - instructions Op nbr 91003-2 14360000 Vacuum pump / 24V 9993884 Converter

14360045 Adapter 11063800 Hose

Figure 1

1.

2.

3.

4.

14360000 Vacuum pump / 24V 9993884 Converter 14360045 Adapter 11063800 Hose

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

Mounting NOTE! The engine must not be running when the adapter is connected to the breather filter. This means a risk of pump breakdown.

1. Put the machine in service position 2, see 191 Service position 2.

2. Remove the cap from the hydraulic tank

Figure 2

3. Connect 14360045 Adapter to 11063800 Hose.

Figure 3

4. Connect the hose to the oil filler.

Figure 4

5. Connect the suction hose to the adapter and place the vacuum pump on a stable surface.

6. Connect the vacuum pump to the 9993884 Converter.

Figure 5 Converter 7. Connect the converter to the socket in the cab.

Figure 6

8. Start the vacuum pump.

9. Let the pump work for 2 - 3 minutes so that the vacuum stabilizes.

10. Check-adjust the vacuum pump to (min) max. -300 mbar (-0.03 MPa) (-4.35 psi) when the system has been opened.

Figure 7

1.

Adjusting screw

NOTE! If the pressure goes lower than -300 mbar, there's a risk that the hydraulic pump axle–seals let trough dirt and engine oil into the hydraulic system.

Removing

11. Turn off the electric power to the vacuum pump.

12. Unplug the plug from the socket.

13. Remove the adapter. Replace the oil fill.

Service Information Document Title: Function Group: Hydraulic system, relieve 900 pressure

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic system, relieve pressure Op nbr 900-003

Mechanical controls The machines are equipped with one (MC60B, MC70B, MC80B and MC90B) or two (MC110B) accumulators.. To be able to work in a safe way with the hydraulic system it is necessary to relieve all pressure before opening the system.

Perform the instruction as follows

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. If the machine is equipped with cab door, close the door.

2. Lower the seat bar.

3. Start the engine.

4. Press the lift/tilt lockout switch.

5. Stop the engine.

6. Put the key in ON position.

7. Press the lift/tilt lockout switch.

8. Auxiliary hydraulics, relieve pressure Alternately press the buttons for the auxiliary function approximately 20 – 30 times.

9. Working hydraulics, relieve pressure Operate the foot pedals between extreme positions.

10. Transmission hydraulics, relieve pressure Operate the controls handles between extreme positions.

11. High flow hydraulics, relieve pressure When the High flow system is not activated the fluid in the system drains slowly to tank. Wait at least two minutes before opening the High flow circuit.

12. Parking brake circuit, relieve pressure (MC110B only) When the engine is off, the fluid in the parking brake circuit drains to tank. No separate instruction is needed.

Service Information Document Title: Function Group: Hydraulic system, relieve 900 pressure

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic system, relieve pressure Op nbr 900-003

Pilot controls The machines are equipped with one (MC60B, MC70B, MC80B and MC90B) or two (MC110B) accumulators.. To be able to work in a safe way with the hydraulic system it is necessary to relieve all pressure before opening the system.

Perform the instruction as follows

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. If the machine is equipped with cab door, close the door.

2. Lower the seat bar.

3. Start the engine.

4. Press the lift/tilt lockout switch.

5. Stop the engine.

6. Put the key in ON position.

7. Press the lift/tilt lockout switch.

8. Auxiliary hydraulics, relieve pressure Rotate the auxiliary roller one time in each direction.

9. Working hydraulics, relieve pressure Operate the right control handle one time in each directions (forwards, backwards, right and left).

10. Servo hydraulics, relieve pressure Operate the right control handle at least fifteen times forwards and backwards.

11. High flow hydraulics, relieve pressure When the High flow system is not activated the fluid in the system drains slowly to tank. Wait at least two minutes before opening the High flow circuit.

12. Parking brake circuit, relieve pressure (MC110B only) When the engine is off, the fluid in the parking brake circuit drains to tank. No separate instruction is needed.

Service Information Document Title: Startup after repair

Function Group: hydraulic 900

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Startup after hydraulic repair To prevent damage on startup after draining the hydraulic system oil reservoir or replacing hydraulic components, comply with the following procedure.

1.

2.

Remove tank fill cap and fill tank with oil according to specification, see 900 Hydraulic system, specification.

Fill the transmission pump housings with clean hydraulic oil via the topmost case drain port. See 030 Oil and hydraulic fluid, recommendation.

3.

Disconnect the engine stop solenoid and turn the engine over with the starter at minimum of three fifteen second intervals. With this procedure the lines from the tank to the pumps are filled with oil. Reconnect the solenoid.

4.

5.

6.

7.

Figure 1 Engine stop solenoid connector Start the engine and run it at half throttle for several minutes with no hydraulics engaged.

Press the control lift/tilt lockout button, to activate the lift and tilt system.

To bleed air from the hydraulic system, operate all the hydraulic functions with engine at half throttle without load.

Operate without running the cylinders to end of stroke.

Shut engine OFF and check for leaks. Recheck fluid level and add as necessary.

Service Information Document Title: Startup after repair

Function Group: hydraulic 900

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Startup after hydraulic repair To prevent damage on start-up after draining the hydraulic system oil reservoir or replacing hydraulic components, comply with the following procedure.

1.

2.

3.

4.

5.

6.

Fill tank with oil according to specification, see 900 Hydraulic system, specification.

Fill the transmission pump housing with clean hydraulic oil via the topmost case drain port.

Start the engine and run at low idle for several minutes with no hydraulics engaged.

Activate the hydraulic system.

Operate all the hydraulic functions without load. Operate without running the cylinders to end of stroke.

Shut engine OFF and check for leaks. Recheck fluid level, add if necessary.

Service Information Document Title: Accumulator, discarding

Function Group: 900

Information Type: Service Information

Profile: SSL, MC80B [GB]

Accumulator, discarding Op nbr 900-050

WARNING Gas under high pressure!

Accumulators that are to be discarded must not constitute a hazard.

1. Relieve the pressure by carefully open the valve on the accumulator.

Figure 1

1.

Gas valve

2. When gas has stopped flowing out, remove the valve.

Date: 2014/3/19

Service Information Document Title: Hydraulic system, instructions

Function Group: work 910

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic system, work instructions       

Always wear clean coveralls and maintain strict personal cleanliness.

Perform thorough troubleshooting in order to avoid unnecessary work.

If needed and if possible move the machine to an environment that is as dust-free as possible.

If possible, do not dismantle components in the field. Use exchange components.

Protect both replaced components and components that are going to be used again by wrapping them in plastic foil.

If the tank is to be drained, and the oil is not discoloured and is free from impurities – drain the oil into container which is then sealed tightly. Always refill this oil or fill new oil through the filler plug on the hydraulic filter cap.

Use a suitable fluid when cleaning and pour it into a thoroughly cleaned container.

Service Information Document Title: Main control description

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, description Mechanical controls

Figure 1

A. B.

Early model Late model

1.

2.

3.

4.

5.

6.

7.

8.

Loader arm spool Tilt spool Auxiliary spool Check valves Relief valve Lift spool lockout solenoid Tilt spool lockout solenoid Auxiliary servo solenoid

Valve description The main control valve is a directional valve. The main control valve assembly contains a relief valve assembly, three spools and one check valve to each spool.

The control valve has an open centre. This means that fluid can pass through the spools when they are in neutral position.

The spools have centering springs which push the spools back to neutral.

Figure 2

A. B.

Early model Late model

1

Auxiliary spool

4

Check valve

2

Tilt spool

5

Open centre

3

Lift spool

6

Centering spring

7

Main relief valve

Lift and tilt spool assemblies are equipped with lock out solenoids. They lock the spools in a closed position to cut off fluid flow. The lift and tilt spool lockout solenoids are released when the door is closed, the ignition key is in the "run" position, the seat bar is lowered and the lift/tilt lockout switch has been depressed.

For more information regarding the lift- and tilt system, see 912 Lift function, description and 912 Tilt function, description.

The loader arm and auxiliary spool are equipped with a detent function. The lift detent function holds the loader arm spool in float position. The auxiliary detent function keeps full flow in one direction by holding the valve spool in position with an electrical influence on the solenoid valve. The auxiliary detent is activated with a button located the control handle.

912 Auxiliary function, description For more information regarding the auxiliary function, see and 360 Auxiliary electrical function, description.

The main control valve in MC60B and MC70B is also equipped with a secondary relief valve connected to the loader arm (+), cylinder bore line. The relief valve protects the lift cylinders against high pressure in "passive" conditions.

Valve operation The valve controls the direction of hydraulic flow to the loader arm cylinders, tilt cylinders and auxiliary attachments. The loader arm spool is shifted by the left foot pedal via a cable, and the tilt spool is shifted by the right foot pedal. The auxiliary spool is shifted by solenoids activated by buttons on the right steering handle.

Service Information Document Title: Main control description

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, description Pilot controls

Figure 1

1.

2.

3.

4.

5.

6.

Auxiliary spool Tilt spool Lift spool Relief valve MA9111 MA9112

Valve description The main control valve is a directional valve. The main control valve assembly contains a relief valve assembly, three spools and one check valve to each spool.

The control valve has an open centre. This means that fluid can pass through the spools when they are in neutral position.

The spools have centering springs which push the spools back to neutral.

The loader arm and auxiliary spool are equipped with detent function.

The loader arm detent function holds the loader arm spool in float position. The detent function is activated by pushing the control lever fully forward against solenoid MA9108.

The auxiliary detent function keeps full flow in one direction by holding the valve spool in position with electrical influence on a PWM valve. The auxiliary detent is activated with a button located the control handle.

The main control valve in MC60B and MC70B is also equipped with a secondary relief valve connected to the loader arm (+), cylinder bore line. The relief valve protects the lift cylinders against high pressure in "passive" conditions.

Figure 2

1

Auxiliary spool

4

Check valve

2

Tilt spool

5

Open centre

3

Lift spool

6

Centering spring

7

Main relief valve

Valve operation The valve controls the direction of hydraulic flow to the loader arm cylinders, tilt cylinders and auxiliary attachments. The loader arm spool and the tilt spool are operated by a four way valve on the right side control lever. The auxiliary spool is shifted by a roller SW9161 that controls solenoids MA9111 and MA9112. The roller is located on the right control handle.

For more information regarding the lift-, tilt- and auxiliary system, see and .

990 Hydraulic diagram 912 Lift function, description 912 Tilt function, description 912 Auxiliary function, description 360 Auxiliary electrical function, description 915 Control levers, description

Service Information Document Title: Main relief description

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Main relief valve, description The main pressure relief valve limits the maximum pressure to protect the components and the system. When the pressure reaches the setting of the relief valve, the valve opens, returning the fluid to the hydraulic tank. This prevents pressure from building above the setting of the valve.

The back pressure in the return line also has an affect of the relief valve. Therefore the pressure setting on the relief valve and the max pressure are different in the machine. The back pressure depends on which model it is and if the machine is equipped with High Flow or not.

Figure 1 Mechanical controlled main block shown A. B.

Early version Late version

1.

Main pressure relief valve

Service Information Document Title: Lift function, description

Function Group: 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Lift function, description Lift function Fluid is pumped through the inlet port of the main control valve into the open centre of the lift spool.

When the lift spool shifts to lift position the check valve unseats as soon as the pump pressure reaches the load pressure and allows fluid to flow through the lockout solenoid valve and out to the base end of the loader arm cylinders. Fluid from the rod end flows back to the lift spool in the main control valve and out to return line.

In machines equipped with self level the fluid flows from the rod end of the loader arm cylinders to the self leveling valve, back to the lift spool in the main control valve and out to return line.

See,916 Self level valve, description.

Lower function Fluid is pumped through the inlet port of the main control valve into the open centre of the lift spool.

When the lift spool shifts to lower position the check valve unseats as soon as the pump pressure reaches the load pressure and allows fluid to flow out to the rod end of the loader arm cylinders. Fluid from the base end of the loader arm cylinders flows through the lockout solenoid valve back to the lift spool in the main control valve and out to the return line.

Check valve The check valve holds the loader arm in position until the loader arm spool is shifted forward or rearward. The check valve opens when the pump pressure exceeds the load pressure.

Using two functions together When using the loader arm, the return fluid from the cylinders goes to tilt spool, and could be used for the tilt function. If the tilt cylinders are in end position with tilt function still activated, the lift function stops because the return fluid from the base end of the lift cylinder can not return to tank through the tilt spool.

Float function In float position, the base end and rod end of the lift cylinders are connected to tank.

It allows the loader arm to float and the implement to follow the contour of the ground. The detent function will hold the spool in the float position until it is released.

On the MC70B High flow the return fluid from the main control valve goes to the high flow function when the spools are in neutral position.

Figure 1

Service Information Document Title: Tilt function, description

Function Group: 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Tilt function, description Tilt up function Fluid is pumped through the inlet port of the main control valve into the open centre of the tilt spool.

When the tilt spool shifts to tilt up position the check valve unseats when the pump pressure reaches the load pressure and allows fluid to flow out to the rod end of the tilt cylinders. Fluid from the base end flows back to the tilt spool in the main control valve and out the return line.

Tilt down function Fluid is pumped through the inlet port of the main control valve into the open centre of the tilt spool.

As soon as the tilt spool shifts to lower position the check valve unseats when the pump pressure reaches the load pressure and allows fluid to flow out to the base end of the tilt cylinders. Fluid from the rod end of the tilt cylinders flows back to the tilt spool in the main control valve and out to return line.

Self level On machines equipped with self level, the fluid flows from the tilt spool in the main control valve to the self leveling valve, and on out to the tilt cylinders. The return fluid from the cylinder flows to the self leveling valve, back to the tilt spool in the main control valve and out the return line. See, 916 Self level valve, description.

Check valve The check valve holds the bucket in position until the lift spool is shifted forward or rearward. The check valve opens when the pump pressure reaches the load pressure.

Using two functions together When using the loader arm, the return fluid from the cylinders goes to tilt spool, and could be used for the tilt function. If the tilt cylinders are in end position with tilt function still activated the lift function stops because return fluid from the base end of the lift cylinder can not return to tank through the tilt spool.

On the MC70B High flow the return fluid from the main control valve goes to the high flow function when the spools are in neutral position.

Figure 1

Service Information Document Title: Auxiliary description

Function Group: function, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Auxiliary function, description

Figure 1

1.

2.

Female auxiliary coupling Male auxiliary coupling

Mechanical controls The auxiliary hydraulic system provides hydraulic flow to a pair of quick couplings mounted on the inside of the left loader arm. The system is operated by solenoids mounted on the main control valve. The solenoids are activated by buttons on the right steering handle.

Figure 2

1.

2.

3.

Auxiliary Left button — female coupling Right button — male coupling Auxiliary, detent (on the front side) Horn

When one of the auxiliary buttons is activated the auxiliary spool shifts and allows fluid to be pumped through the main control valve and into the auxiliary spool. There it is held at the auxiliary spool check valve until the pump pressure overcomes the load pressure holding the check valve on its seat. To lock the auxiliary hydraulic flow hold the right/(left) button and press the detent button. It is only possible to activate the detent function when pressing the right button (flow from male coupling).

Depending on which button is pressed, the fluid flows either to the female or male quick coupling and out to the auxiliary attachment. Fluid returns from the auxiliary attachment, through the female or male quick coupling back to the main control valve. The fluid then returns to the hydraulic tank after passing through the hydraulic cooler and the filter (MC80B/MC90B/ MC110B).

To make it easier to remove attachments from the auxiliary couplings, an accumulator helps relieve the hydraulic pressure from the auxiliary system.

For more information regarding the auxiliary function, see 360 Auxiliary electrical function, description.

Service Information Document Title: Auxiliary description

Function Group: function, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Auxiliary function, description Mechanical controls

Figure 1

1.

2.

Female auxiliary coupling Male auxiliary coupling

The auxiliary hydraulic system provides hydraulic flow to a pair of quick couplings mounted on the left loader arm. The system is operated by solenoids mounted on the main control valve. The solenoids are activated by buttons on the right steering handle.

Figure 2

1.

2.

3.

Auxiliary Left button — female coupling Right button — male coupling Auxiliary, detent (on the front side) Horn

When one of the auxiliary buttons is activated the auxiliary spool shifts and allows fluid to be pumped through the main control valve and into the auxiliary spool. There it is held at the auxiliary spool check valve until the pump pressure overcomes the load pressure holding the check valve on its seat. To lock the auxiliary hydraulic flow hold the right/left button and press the detent button.

Depending on which button is pressed, the fluid flows either to the female or male quick coupling and out to the auxiliary attachment. Fluid returns from the auxiliary attachment, through the female or male quick coupling back to the main control valve. The fluid then returns to the hydraulic tank after passing through the hydraulic cooler and the filter (MC80B/MC90B/ MC110B).

Figure 3 Left instrument panel To be able to vary the auxiliary max pressure to different conditions, max flow can be set on the display on the instrument panel. The set value goes to V-ECU witch converts the signal to PWM9123, PWM9124 witch operates the spool in the main control valve.

To make it easier to remove attachments from the auxiliary couplings, an accumulator helps relieve the hydraulic pressure from the auxiliary system.

For more information regarding the auxiliary function, see 360 Auxiliary electrical function, description.

Service Information Document Title: Auxiliary description

Function Group: function, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Auxiliary function, description Pilot controls

Figure 1

1.

2.

Female auxiliary coupling Male auxiliary coupling

The auxiliary hydraulic system provides a variable hydraulic flow to a pair of quick couplings mounted on the inside of the left loader arm. The system is operated by a PWM valve, mounted on the main control valve. The solenoids are activated by a roller on the right steering handle.

Figure 2

1.

2.

3.

4.

Auxiliary, hydraulic flow in reverse direction Auxiliary, hydraulic flow in forward direction Horn Auxiliary, detent (on the front side)

When the auxiliary roller is rotated a signal is sent to the PWM valve causing the auxiliary spool to shift. This allows fluid to be pumped through the main control valve and into the auxiliary spool. The flow is held at the auxiliary spool check valve until the pump pressure overcomes the load pressure holding the check valve on its seat.

Depending on the direction of the control signal and thus the position of the spool, the fluid flows either to the female or male quick coupling and out to the auxiliary attachment. Fluid returns from the auxiliary attachment, through the female or male quick coupling back to the main control valve. The fluid then returns to the hydraulic tank after passing through the hydraulic cooler and the filter (MC80B/MC90B/MC110B).

To lock the auxiliary hydraulic flow in one direction, hold the roller in either end position and press the detent button. It is only possible to activate the detent function when rolling the switch to the right (flow from male coupling).

Release the detent roller by depressing the detent button or rotating the roller.

An accumulator is connected to the auxiliary system to facilitate the removal of attachments from the auxiliary couplings when the engine is shut off. It keeps up the servo pressure, that makes it is possible to operate the spool and thereby relief the auxiliary circuit.

For more information regarding the auxiliary function, see 360 Auxiliary electrical function, description.

Service Information Document Title: Auxiliary description

Function Group: function, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Auxiliary function, description Pilot controls

Figure 1

1.

2.

Female auxiliary coupling Male auxiliary coupling

The auxiliary hydraulic system provides a variable hydraulic flow to a pair of quick couplings mounted on the inside of the left loader arm. The system is operated by a PWM valve, mounted on the main control valve. The solenoids are activated by a roller on the right steering handle.

Figure 2

1.

2.

3.

4.

Auxiliary, hydraulic flow in reverse direction Auxiliary, hydraulic flow in forward direction Horn Auxiliary, detent (on the front side)

When the auxiliary roller is rotated a signal is sent to the PWM valve causing the auxiliary spool to shift. This allows fluid to be pumped through the main control valve and into the auxiliary spool. The flow is held at the auxiliary spool check valve until the pump pressure overcomes the load pressure holding the check valve on its seat.

Depending on the direction of the control signal and thus the position of the spool, the fluid flows either to the female or male quick coupling and out to the auxiliary attachment. Fluid returns from the auxiliary attachment, through the female or male quick coupling back to the main control valve. The fluid then returns to the hydraulic tank after passing through the hydraulic cooler and the filter (MC80B/MC90B/MC110B).

To be able to vary the auxiliary max pressure to different conditions, max flow can be set on the display on the instrument panel. The set value goes to V-ECU witch converts the signal to PWM9123, PWM9124 witch operates the spool in the main control valve.

Figure 3 Left instrument panel To lock the auxiliary hydraulic flow in one direction, hold the roller in either end position and press the detent button.

Release the detent roller by depressing the detent button or rotating the roller.

An accumulator is connected to the auxiliary system to facilitate the removal of attachments from the auxiliary couplings when the engine is shut off. It keeps up the servo pressure, that makes it is possible to operate the spool and thereby relief the auxiliary circuit.

For more information regarding the auxiliary function, see 360 Auxiliary electrical function, description.

Service Information Document Title: Function Group: Main control valve system 912 relief test

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve system relief test Op nbr 912-068 11666051 Pressure gauge 14290266 Hose

This operation also includes required tools and times for applicable parts of the following operations:  

191 Service position 2 900 Hydraulic system, relieve pressure

NOTE! The hydraulic fluid should be at operating temperature 40-60 °C (104–140 °F).

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Park the machine in service position 2, see 191 Service position 2 2. Install the pressure gauge at one of the test locations.

Figure 1

1.

Test location

3. Start the engine.

4. Lower the seat bar.

5. Press the hydraulic lock out switch.

6. Increase the engine speed to full throttle and activate one of the auxiliary functions.

For correct pressure value, see 900 Hydraulic pressure, specifications .

If the pressure is not correct, the main relief valve has to be replaced or adjusted.

If the valve is of an early version, the main relief valve has to replaced see 912 Main pressure relief valve, replacing.

If the valve is of a late version, the valve can be adjusted, see 912 Main relief valve, adjusting.

Figure 2

A. B.

Early version Late version

1.

Main relief valve

7. Stop the engine.

8. Relieve the hydraulic pressure in the auxiliary system, see 900 Hydraulic system, relieve pressure.

9. Remove the gauge and hose from the test location.

Service Information Document Title: Function Group: Main control valve system 912 relief test

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve system relief test Op nbr 912-068 11666051 Pressure gauge 14290266 Hose

935422 Reduction 935332 Nut 935026 G 1/4/ – 13/16 – 16 This operation also includes required tools and times for applicable parts of the following operations:  

191 Service position 2 900 Hydraulic system, relieve pressure

NOTE! The hydraulic fluid should be at operating temperature 40-60 °C (104–140 °F).

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Put the machine in service position 2, see 191 Service position 2 2. Relieve the pressure in the auxiliary system, see 900 Hydraulic system, relieve pressure.

3. Install the pressure gauge at one of the test locations.

Figure 1

1.

Test location

4. Set the ignition key to on position.

5. For pilot machines only Set the auxiliary flow to max on the display on the instrument panel, see Operator's Manual.

Figure 2 Instrument panel, left side 6. Start the engine.

7. Lower the seat bar.

8. Press the hydraulic lock out switch.

9. Raise the seat bar.

10. Activate one of the auxiliary functions.

11. Increase the engine speed to full throttle.

For correct pressure value, see 900 Hydraulic pressure, specifications .

If the pressure is not correct, the main relief valve has to be adjusted, see 912 Main relief valve, adjusting.

12. If the pressure is still not correct, 912 Main pressure relief valve, replacing.

the

main

relief

valve

has

to

be

13. Stop the engine.

14. Relieve the hydraulic pressure in the auxiliary system, see 900 Hydraulic system, relieve pressure.

15. Remove the gauge and hose from the test location.

replaced,

see

Service Information Document Title: Function Group: Main relief valve, adjusting 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Main relief valve, adjusting Op nbr 912-136 This operation also includes required tools and times for applicable parts of the following operations:   

191 Service position 1 900 Hydraulic system, relieve pressure 912 Main control valve system relief test 1. Park the machine in service position 1, see 191 Service position 1.

The main control valve is located on the right side, inside the transmission compartment.

2. NOTE! The engine should always be shut off during the adjusting procedure.

Loosen the lock nut on the main relief valve.

Figure 1

1.

2.

Lock nut Adjusting screw

3. Adjust the main relief valve by rotating the adjusting screw. Clockwise to increase the pressure and counter clockwise to decrease the pressure.

NOTE! Rotating the adjustment screw 1/4 revolution implies approx. 2.5 MPa (25 bar) (363 psi) change of the pressure!

4. Tighten the lock nut.

5. Verify the adjusting by performing 912 Main control valve system relief test.

the

main

control

valve

system

relief

test,

see

Service Information Document Title: Main control removal

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, removal Mechanical controls Op nbr 912-091 14360000 Vacuum pump / 24V 9993884 Converter

14360045 Adapter 11063800 Hose This operation also includes required tools and times for applicable parts of the following operations:   

191 Service position 1 900 Connecting/disconnecting vacuum pump - instructions 900 Hydraulic system, relieve pressure

NOTE! Make sure that new O-rings are available before removal.

1. Put the machine in service position 1, see 191 Service position 1.

2. Install the vacuum pump to the hydraulic tank, see 900 Connecting/disconnecting vacuum pump - instructions.

3. Remove the right side panel.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! The hydraulic system is equipped with an accumulator. Relive any trapped pressure before opening the hydraulic system, see 900 Hydraulic system, relieve pressure 4. Remove any dirt from the main control valve, hydraulic fittings and lines.

5. Tag, disconnect and plug all hydraulic hoses from the main control valve.

NOTE! Do not remove the internal hoses.

Figure 1

1.

2.

3.

4.

5.

Auxiliary connector MA9111 Auxiliary connector MA9112 Internal hose Solenoid connector MA9103 Solenoid connector MA9104

6. Tag and disconnect the auxiliary solenoid valve connectors, MA9111 and MA9112.

7. Tag and disconnect the tilt solenoid connector MA9103, and lift solenoid connector MA9104.

8. Remove screws holding the main control valve to the frame.

9. Lift the valve assembly forwards, placed front side down.

Figure 2

1.

2.

Sleeve Cable

10. Loosen the sleeves from the lift spool and the tilt spool. Disconnect the cables from the spools.

11. Lift the valve assembly out of the machine.

Service Information Document Title: Main control removal

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, removal Pilot controls Op nbr 912-091 14360000 Vacuum pump / 24V

9993884 Converter 14360045 Adapter 11063800 Hose 1. Put the machine in service position 1, see 191 Service position 1.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Relive any trapped pressure before opening the hydraulic system 2. Install the vacuum pump to the hydraulic tank, see 900 Connecting/disconnecting vacuum pump - instructions.

3. Remove the right side panel.

Figure 1

4. Remove any dirt from the main control valve, hydraulic fittings and lines.

5. Tag and disconnect all hydraulic hoses from the main control valve. Plug and cap all hoses with tight plugs and caps.

NOTE! Do not remove the servo hoses.

Figure 2

1.

2.

3.

Internal hoses Auxiliary solenoid valve connectors MA9111 and MA9112 Mounting screw

6. Tag and disconnect the auxiliary solenoid valve connectors, MA9111 and MA9112.

7. Remove the mounting screws that holds the main control valve to the frame.

8. Lift the valve out of the machine.

Service Information Document Title: Main control removal

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, removal Pilot controls Op nbr 912-091 14360000 Vacuum pump / 24V

9993884 Converter 14360045 Adapter 11063800 Hose This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą ď‚Ą

191 Service position 1 900 Connecting/disconnecting vacuum pump - instructions 1. Put the machine in service position 1, see 191 Service position 1.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Relieve any trapped pressure before opening the hydraulic system, see 900 Hydraulic system, relieve pressure.

2. Install the vacuum pump to the hydraulic tank, see 900 Connecting/disconnecting vacuum pump - instructions.

Figure 1

3. Remove the right side cover.

Figure 2

1.

Side cover

4. MC70B only Disconnect the connector to the throttle control.

Remove the throttle control assembly, mounting bracket included and put aside.

Figure 3

1.

2.

3.

4.

Connector, throttle control, MC70 only Throttle control, MC70 only Mounting bracket, MC70 only Implement hose

5. Disconnect the outlet implement hose from the implement pump.

Figure 4

1.

Implement hose, connection

6. Remove any dirt from the main control valve, hydraulic fittings and lines.

7. Tag and disconnect all hydraulic hoses from the main control valve, except the internal tubes. Plug and cap all hoses and tubes with tight plugs and caps.

Figure 5

1.

Internal tubes

8. Tag and disconnect the auxiliary solenoid valve connectors, PWM9123 and PWM9124.

9. Remove the mounting screws that holds the main control valve to the frame.

10. Lift the valve out of the machine.

Service Information Document Title: Main control installation

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, installation Mechanical controls Op nbr 912-092 1. Replace hydraulic fittings if they are damaged.

2. Lubricate new O-rings with clean oil and install them on the hydraulic fittings.

3. If the control valve has been replaced, install all necessary hydraulic fittings into the new control valve body in the same ports and orient them to the same position as before.

4. Put the valve assembly into the transmission compartment front side down.

Figure 1 V1044266 1.

2.

Sleeve Cable

5. Fit the cable into the slot on the tilt spool and fit the sleeve.

Fit the cable into the slot on the lift spool and fit the sleeve.

Figure 2 V1044271 1.

2.

3.

Cable Slot Sleeve

6. Fit the valve assembly to the frame.

Figure 3 V1044265 1.

2.

3.

4.

5.

MA9111 MA9112 Leak oil connection MA9103 MA9104

7. Connect the leak oil hose to the upper and lower auxiliary housing.

8. Connect the connectors to the auxiliary solenoid valves, (MA9111) and (MA9112).

9. Connect the connectors to the tilt spool lockout solenoid (MA9103) and the lift spool lockout solenoid (MA9104).

10. Connect the remaining hydraulic hoses to the main control valve. Tighten securely.

Figure 4 V1044275 11. Install the right side panel.

Figure 5 V1043421 12. Remove the vacuum pump from the hydraulic tank.

13. Lower the cab from the service position, see 191 Service position 1.

14. See 900 Startup after hydraulic repair. Check for leaks.

Service Information Document Title: Main control installation

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, installation Pilot controls Op nbr 912-092 1. Replace hydraulic fittings if they are damaged.

2. Lubricate new O-rings with clean oil and install them on the hydraulic fittings.

3. If the control valve has been replaced, install all hydraulic fittings into the new control valve body in the same ports and orient them to the same position as before.

4. Install the control valve assembly into the machine.

5. Connect all hydraulic hoses to the control valve assembly. Tighten securely.

Figure 1

1.

2.

Auxiliary solenoid MA9111 Auxiliary solenoid MA9112

6. Connect the auxiliary solenoid connectors.

7. Install the right side panel.

Figure 2

8. Remove the vacuum pump from 900 Connecting/disconnecting vacuum pump - instructions.

9. Lower the cab from the service position, see 191 Service position 1.

10. See 900 Startup after hydraulic repair. Check for leaks.

the

hydraulic

tank,

see

Service Information Document Title: Main control installation

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Main control valve, installation Op nbr 912-092

Pilot controls This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą ď‚Ą

900 Connecting/disconnecting vacuum pump - instructions 900 Startup after hydraulic repair 1. Replace hydraulic fittings if they are damaged.

2. Lubricate new O-rings with clean oil and install them on the hydraulic fittings.

3. If the control valve has been replaced, install all hydraulic fittings into the new control valve body in the same ports and orient them to the same position prior to removal 4. Install the control valve assembly into the machine.

5. Reconnect all hydraulic hoses and tubes to the control valve assembly.

Figure 1

1.

Internal tubes

6. Connect the auxiliary solenoid valve connectors, PWM9123 and PWM9124.

7. Reconnect the hose to the implement pump.

Figure 2

1.

2.

3.

4.

Connector, throttle control, MC70 only Throttle control, MC70 only Mounting bracket, MC70 only Implement hose

8. MC70B only Fit the throttle control assembly to the frame.

9. Install the right side cover.

Figure 3

1.

Side cover

10. Remove the vacuum pump from 900 Connecting/disconnecting vacuum pump - instructions.

11. Lower the cab from the service position, see 191 Service position 1.

12. See 900 Startup after hydraulic repair. Check for leaks.

the

hydraulic

tank,

see

Service Information Document Title: Main control maintenance

Function Group: valve, 912

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Main control valve, maintenance Op nbr 912-094

Auxiliary spool NOTE! Spool is fit to valve housing at very close manufacturing tolerances. Care must be taken to avoid damage..

1. Disassembly Remove the servo hoses from the main control valve

Figure 1 V1044680 1.

2.

Servo hose Main control valve

2. Remove the solenoid valves from the auxiliary spool.

NOTE! Carefully take care of all small parts

Figure 2 V1044681 1.

2.

3.

4.

5.

Solenoid valve O-ring Piston Spring Auxiliary spool

3. Remove and discard the O-rings.

4. Remove pistons and springs from the solenoid valves.

5. Remove the auxiliary spool from the valve body.

6. Reassembly Apply a bead of vaseline on the new O-rings. Install the O-ring into the solenoid valves.

7. Insert springs and pistons into the solenoid valves.

8. Put clean hydraulic oil on the auxiliary spool and install the spool into the valve body.

9. Fit the solenoid valves on the main control valve.

NOTE! Spool is fit to valve housing at very close manufacturing tolerances. Care must be taken to avoid damage.

Tilt spool Disassembly 10. Remove the tilt spool housing

Figure 3 V1044682 1.

2.

3.

4.

5.

Tilt spool housing O-ring Piston Spring Tilt spool

NOTE! Carefully take care of all small parts 11. Remove and discard the O-rings from the housings.

12. Remove pistons and springs from the housing.

13. Remove the tilt spool from the valve body.

14. Reassembly Apply a bead of vaseline on the new O-rings. Install the O-rings into the tilt spool housing.

15. Insert springs and pistons into the tilt spool housing.

16. Put clean hydraulic oil on the tilt spool and install the spool into valve body.

17. Fit the tilt spool housing on the main control valve.

Lift spool 18. Disassembly Carefully remove the upper lift spool housing NOTE! The spring tension inside the housing is high.

NOTE! Carefully take care of all small parts

Figure 4 V1044683 1.

2.

3.

4.

5.

6.

7.

8.

Upper lift spool housing Lower lift spool housing O-ring Spring Piston Spool cap spacer Spring guide Lift spool

19. Remove and discard the O-rings from the upper housing .

20. Remove spring guide, spring, piston and spring from the upper housing.

21. Remove the lower lift spool housing and spool cap spacer..

22. Remove and discard the O-rings from the housing and the spacer .

23. Remove the piston and spring from the lift spool housing.

24. Remove the tilt spool from the valve body.

25. Reassembly Apply a bead of vaseline on the new O-rings. Install the O-rings into the lift spool housing and into the spool cap spacer..

26. Insert spring and piston into the lower lift spool housing.

27. Put clean hydraulic oil on the lift spool and install the spool into valve body.

28. Fit the spool cap spacer and the lower lift spool housing on the control valve.

29. Fit the upper lift spool housing on the control valve.

NOTE! The spring tension is high.

Figure 5 V1045783 1.

2.

Main pressure relief valve Load check valve

Main pressure relief valve 30. Remove the main relief valve assembly from the control valve .

31. Install the relief valve assembly into the valve body.

NOTE! After changing the main pressure relief 900 Main control valve system relief test

valve

Load Check 32. Disassembly Remove plug, spring and poppet from the control vavle.

a

relief

test

has

to

be

performed,

see

Figure 6 V1044691 1.

2.

3.

4.

Plug O–ring Spring Poppet

33. Remove and discard the O–ring.

34. Assembly Install poppet and spring into the valve body.

35. Install a new O-ring and install the plug.

Service Information Document Title: Function Group: Main pressure relief valve, 912 replacing

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Main pressure relief valve, replacing Op nbr 912-067 14360000 Vacuum pump / 24V 9993884 Converter

14360045 Adapter 11063800 Hose This operation also includes required tools and times for applicable parts of the following operations:   

191 Service position 1 900 Connecting/disconnecting vacuum pump - instructions 912 Main control valve system relief test 1. Park the machine in the service position, see 191 Service position 1.

2. Install the vacuum pump to the oil filler, see 900 Connecting/disconnecting vacuum pump - instructions.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 3. Tag, remove and plug requisite hydraulic hoses from the main control valve, to access the main relief valve.

4. Remove the main relief valve.

Figure 1

A. B.

Early version Late version

1.

Main pressure relief valve

5. Install the main relief valve into the valve body.

6. Install the hydraulic hoses.

7. Disconnect the vacuum pump, see 900 Connecting/disconnecting vacuum pump - instructions.

8. Lower the cab from service position, see 191 Service position 1.

9. Test the pressure setting, see 912 Main control valve system relief test.

Service Information Document Title: Function Group: Working hydraulics, 912 troubleshooting

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Working hydraulics, troubleshooting Mechanical controls Trouble Loss of hydraulic power to loader arm, attachment tilt, and auxiliary hydraulics .

Probable cause

Remedy

Referring section

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position attached.

Main relief valve failure or out of Check pressure setting. adjustment.

Implement pump cavitation.

Check supply hose to pump for leaks or bad connections.

Check oil level

Implement pump failure.

Inspect and replace pump.

Charge failure.

and

implement

pump

Transmission pump shaft failure.

912 Main control valve system relief test

MC60B MC70B 913 Charge/Implement pump charge relief test

shaft If the wheels drive, check the charge 913 Implement pump, removal and implement pump shaft. f the wheels do not drive, check the 442 Transmission pump, drive relief transmission pump or drive shaft test universal joint. or 442 Transmission pump, removing Trouble Hydraulic action jerky (all functions).

Probable cause

Remedy

Air in hydraulic system.

Check for leaks between oil reservoir and charge/implement or implement pump.

Bleed system by raising and lowering loader arm and fully tilting attachment forward and backward several times without running the cylinders to their end-positions .

Check hydraulic oil level.

Hydraulic tank low on oil.

Check for leaks.

Fill hydraulic oil tank.

Restricted oil supply hose from hydraulic Replace or repair damaged oil supply tank to charge/implement or implement hose. pump.

Trouble

Referring section

See section Service and Maintenance

Hydraulic action jerky (one function).

Probable cause

Remedy

Referring section

Foot pedal cable linkage worn, loose, or Inspect and tighten or replace as 950 Foot pedal, cable removal binding. required.

Control valve spool spring return Check mechanism mechanism not functioning properly.

912 Main control valve, maintenance

Load check valve in main control valve Check load check valve. not functioning properly.

912 Main control valve, maintenance

Cylinder base or rod trunnion end Replace bushings and bushing seals. bushing failure.

Loader arm bushing failure.

Replace bushings and bushing seals.

Binding of cylinder rod or piston.

Remove, repair or replace cylinder.

945 Lift cylinder, removing 945 Tilt cylinder, removing

Trouble Loader arm will not raise or lower Probable cause

Remedy

Referring section

Lift and tilt lockout solenoid engaged.

Push lift/tilt lockout switch.

Lift and tilt lockout solenoid failure.

Test and replace if necessary.

Foot pedal cable disconnected, rusted, or Inspect and broken. necessary.

Self level valve malfunction.

Cylinder rod bent.

repair

or

366 Lift and tilt lockout functions, components testing and adjustment

replace

as 950 Foot pedal, cable removal

Bypass self level valve.

Check and replace if necessary.

916 Self level valve, bypass, and

Inspect and replace cylinder rod.

945 Lift cylinder, removing, or

916 Self level valve, removal and installation 945 Tilt cylinder, removing

Lift and tilt lock out relay malfunction.

Replace relay.

372 Relays testing

Loose wires or corroded connection in lift Inspect and test as required. and tilt lockout electrical circuit.

366 Lift and tilt lockout functions, testing

The spool lockout on main control valve Test spool lockout on main control 366 Lift and tilt lockout functions, failure. valve. Replace if necessary. components testing and adjustment Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

spring

return 912 Main control valve, maintenance

Trouble Loader arm and/or tilt function slow.

Probable cause Hydraulic tank low in oil.

Remedy

Referring section

Check for leaks. Fill hydraulic oil tank.

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Foot pedal cable binding or pedal out of Inspect and adjust. adjustment.

950 Foot pedal, cable removal

Main relief valve failure or out of Check pressure. adjustment.

912 Main control valve system relief test 900 Charge system pressure priority valve relief test (MC80)

Internal leakage in main control valve.

912 Main control valve, maintenance

Inspect control valve.

Trouble Loader arm or attachment tilt cylinders will not support a load (leak down).

Probable cause

Remedy

Referring section

Failure one or more check valve in main Check main control valve. control valve.

912 Main control valve, maintenance

Control valve spool not centering.

Check foot pedals or cables for binding 950 Foot pedal, cable removal or adjustment.

912 Main control valve, maintenance Check for damaged spring return mechanism on main control valve spools.

Internal leakage in cylinders.

Check piston seals for leakage.

Internal leakage in main control valve.

Check main control valve.

912 Main control valve, maintenance

Internal leakage in self level valve.

Bypass self level valve, verify leakage.

916 Self level valve, bypass 916 Self level valve, removal and installation

Trouble Hydraulic oil temperature light ON. Reservoir overheating.

Probable cause

Remedy

Referring section

Hydraulic temperature sender switch Test and replace if necessary. Check if defective. the oil is warm.

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Hydraulic tank low on oil.

Check for leaks.

Fill hydraulic oil tank.

Wrong type of hydraulic oil.

Replace oil referring to specification.

030 Oil and hydraulic fluid, recommendation

Oil cooler plugged or dirty. Also check Clean cooling fins. engine radiator.

See section Service and Maintenance.

Main relief valve failure or out of Check pressure and adjust or replace. adjustment.

912 Main control valve system relief test

High flow relief valve failure or out of Check pressure and adjust or replace. adjustment.

916 High flow valve relief test

Unapproved auxiliary attachment being Check specification for attachment and used. attachment operating pressures too machine. high, causing hydraulic system to overheat.

Trouble Tilt will not function Probable cause

Remedy

Foot pedal cable disconnected, rusted, or Inspect and broken. necessary.

repair

Referring section

or

replace

as 950 Foot pedal, cable removal

Self level valve malfunction.

Bypass self level valve, inspect and 916 Self level valve, bypass repair self level valve.

916 Self level valve, adjustment

Cylinder rod bent.

Inspect and replace cylinder rod.

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

945 Lift cylinder, removing, or 945 Tilt cylinder, removing

spring

Control lockout solenoid failure (on main Test and replace if necessary. control valve).

Trouble

return 912 Main control valve, maintenance 366 Lift and tilt lockout functions, components testing and adjustment

Auxiliary not functioning properly Probable cause

Remedy

Quick coupling disconnected connectors are reversed.

Auxiliary inoperative.

electrical

Referring section

or Check quick coupling.

Reverse connectors from implement.

components Inspect and repair or replace fuse, 360 Auxiliary electrical function, switch, relay or solenoid. description

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

spring

return 912 Main control valve, maintenance

Trouble High flow will not function Probable cause Electrical component inoperative.

of

Remedy

Referring section

system Inspect and repair or replace fuse, 360 High flow electrical system, switch, relay or solenoid. description and operation Trouble High flow not functioning properly

Probable cause Quick coupling disconnected connectors are reversed.

Remedy

Referring section

or Check quick coupling.

Reverse connectors from implement.

Unapproved high flow attachment being Check specification for attachment and used. machine.

High flow relief valve failure.

Test and adjust or replace relief valve.

High flow pump worn.

Test and replace pump.

916 High flow valve relief test

Service Information Document Title: Function Group: Working hydraulics, 912 troubleshooting

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Working hydraulics, troubleshooting Pilot controls Trouble Loss of hydraulic power to loader arm, attachment tilt, and auxiliary hydraulics .

Probable cause

Remedy

Referring section

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position attached.

Main relief valve failure or out of Check pressure setting. adjustment.

Implement pump cavitation.

Check supply hose to pump for leaks or bad connections.

Check oil level

Implement pump failure.

Inspect and replace pump.

Charge failure.

and

implement

pump

912 Main control valve system relief test

MC60B MC70B 913 Charge/Implement pump charge relief test

shaft If there is drive on the wheels check the 913 Implement pump, removal charge and implement pump shaft.

Transmission pump shaft failure.

If there is no drive on the wheels, check 442 Transmission pump, drive relief transmission pump or drive shaft test universal joint or 442 Transmission pump, removing

[T1]ď ŠServo circuit not activated

Inspect and repair or replace fuse, switch, relay or solenoid.

[T1]In this case, also loss of power to travel hydraulics.

Trouble Hydraulic action jerky (all functions).

Probable cause

Remedy

Air in hydraulic system.

Check for leaks between oil reservoir and charge/implement or implement pump.

Bleed system by raising and lowering loader arm and fully tilting attachment forward and backward several times without running the cylinders to their end-positions .

Check hydraulic oil level.

Hydraulic tank low on oil.

Check for leaks.

Fill hydraulic oil tank.

Restricted oil supply hose from hydraulic Replace or repair damaged oil supply

Referring section

See section Service and Maintenance

tank to charge/implement or implement hose. pump.

Trouble Hydraulic action jerky (one function).

Probable cause

Remedy

Referring section

Control valve spool spring return Check mechanism mechanism not functioning properly.

912 Main control valve, maintenance

Load check valve in main control valve Check load check valve. not functioning properly.

912 Main control valve, maintenance

Cylinder base or rod trunnion end Replace bushings and bushing seals. bushing failure.

Loader arm bushing failure.

Replace bushings and bushing seals.

Binding of cylinder rod or piston.

Remove, repair or replace cylinder.

945 Lift cylinder, removing 945 Tilt cylinder, removing

Trouble Loader arm will not raise or lower Probable cause

Remedy

Referring section

Lift and tilt lockout solenoid engaged.

Push lift/tilt lockout switch.

Lift and tilt lockout solenoid failure.

Test and replace if necessary.

366 Lift and tilt lockout functions, components testing and adjustment

Self level valve malfunction.

Bypass self level valve.

Check and replace if necessary.

916 Self level valve, bypass, and

Cylinder rod bent.

Inspect and replace cylinder rod.

945 Lift cylinder, removing, or

Lift and tilt lock out relay malfunction.

Replace relay.

916 Self level valve, removal and installation 945 Tilt cylinder, removing 372 Relays testing

Loose wires or corroded connection in lift Inspect and test as required. and tilt lockout electrical circuit.

366 Lift and tilt lockout functions, testing

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

spring

return 912 Main control valve, maintenance

Servo pressure to main control valve to 440 Charge system pressure relief low. valve test Trouble Loader arm and/or tilt function slow.

Probable cause Hydraulic tank low in oil.

Remedy

Referring section

Check for leaks. Fill hydraulic oil tank.

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Main relief valve failure or out of Check pressure. adjustment.

912 Main control valve system relief test

Internal leakage in main control valve.

912 Main control valve, maintenance

Inspect control valve.

Trouble

Loader arm or tilt cylinders will not support a load (leak down).

Probable cause

Remedy

Failure one or more check valve in main Check main control valve.

Referring section 912 Main control valve, maintenance

control valve.

Control valve spool not centering.

Check foot pedals or cables for binding 950 Foot pedal, cable removal or adjustment.

912 Main control valve, maintenance Check for damaged spring return mechanism on main control valve spools.

Internal leakage in cylinders.

Check piston seals for leakage.

Internal leakage in main control valve.

Leakage over check valves,

Check main control valve.

912 Main control valve, maintenance

Internal leakage in self level valve.

Bypass self level valve, verify leakage.

916 Self level valve, bypass 916 Self level valve, removal and installation

Trouble Hydraulic oil temperature light ON. Reservoir overheating.

Probable cause

Remedy

Referring section

Hydraulic temperature sender switch Test and replace if necessary. Check if defective. the oil is warm.

Auxiliary button in detent position Release auxiliary button from detent without any auxiliary implement position. attached.

Hydraulic tank low on oil.

Check for leaks.

Fill hydraulic oil tank.

Wrong type of hydraulic oil.

Replace oil according to specification.

030 Oil and hydraulic fluid, recommendation

Oil cooler plugged or dirty. Also check Clean cooling fins. engine radiator.

See section Service and Maintenance.

Main relief valve failure or out of Check pressure and adjust or replace. adjustment.

912 Main control valve system relief test

High flow relief valve failure or out of Check pressure and adjust or replace. adjustment.

916 High flow valve relief test

Unapproved auxiliary attachment being Check specification for attachment and used. attachment operating pressures too machine. high, causing hydraulic system to overheat.

Trouble Tilt will not function Probable cause

Remedy

Referring section

Self level valve malfunction.

Bypass self level valve, inspect and 916 Self level valve, bypass repair self level valve.

916 Self level valve, adjustment

Cylinder rod bent.

Inspect and replace cylinder rod.

945 Lift cylinder, removing, or 945 Tilt cylinder, removing

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

Servo pressure low

Check pressure

spring

return 912 Main control valve, maintenance 440 Charge system pressure relief valve test

Trouble Auxiliary not functioning properly Probable cause Quick coupling disconnected connectors are reversed.

Remedy or Check quick coupling.

Reverse connectors from implement.

Referring section

Auxiliary inoperative.

electrical

components Inspect and repair or replace fuse, 360 Auxiliary electrical function, switch, relay or solenoid. description

Spool not shifting in main control valve.

Check for damaged mechanisms on spools.

spring

return 912 Main control valve, maintenance

Trouble High flow will not function Probable cause Electrical component inoperative.

of

Remedy

Referring section

system Inspect and repair or replace fuse, 360 High flow electrical system, switch, relay or solenoid. description and operation Trouble High flow not functioning properly

Probable cause Quick coupling disconnected connectors are reversed.

Remedy

Referring section

or Check quick coupling.

Reverse connectors from implement.

Unapproved high flow attachment being Check specification for attachment and used. machine.

High flow relief valve failure.

Test and adjust or replace relief valve.

High flow pump worn.

Test and replace pump.

916 High flow valve relief test

Service Information Document Title: Function Group: Hydraulic pumps, overview 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic pumps, overview Mechanical controls Depending on machine model the location of the hydraulic pumps can vary. This overview makes it easier to locate the different pumps and to understand the hydraulic system.

Figure 1

1

Engine

3

Implement pump

2

Transmission pump

4

Charge pump (priority valve MC80)

5

High flow pump

Service Information Document Title: Function Group: Hydraulic pumps, overview 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic pumps, overview Pilot controls Depending on machine model the location of the hydraulic pumps can vary. This overview makes it easier to locate the different pumps and to understand the hydraulic system.

Figure 1

1.

2.

3.

4.

5.

Engine Transmission pump Implement pump Charge pump High flow pump

Service Information Document Title: Function Group: Hydraulic pumps, overview 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic pumps, overview Mechanical controls This overview makes it easier to locate the different pumps and to understand the hydraulic system.

Figure 1

1.

2.

3.

4.

Engine Transmission pump Implement pump Charge pump

Service Information Document Title: Function Group: Hydraulic pumps, overview 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic pumps, overview Pilot controls Depending on machine model the location of the hydraulic pumps can vary. This overview makes it easier to locate the different pumps and to understand the hydraulic system.

Figure 1

1.

2.

3.

4.

5.

Engine Transmission pump Implement pump Charge pump High Flow pump

Service Information Document Title: Implement descripton

Function Group: pump, 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Implement pump, descripton MC80B, MC90B, MC110B

Figure 1 Transmission unit 1.

Implement pump

The implement pump mounts at the end of the transmission pumps forming a unit. The transmission pump shaft drives the implement pump at engine crankshaft speed. Engine speed determines the pump output.

NOTE! The Model MC80B implement pump also serves as a charge 440 Hydrostatic transmission, description for additional information.

Figure 2 Gear pump

pump

for

the

transmission

pump.

See

1.

2.

3.

4.

5.

Operating gear wheel Pump housing Inlet Trapped fluid transported to the outlet Outlet

The implement pump is a gear pump, which means that two gear wheels rotate meshing together in a tight pump house.

When the gears rotate, fluid from the inlet chamber is being transported between the teeth to the outlet pressurized chamber.

The pump gets fluid from the tank and pumps it to the main control valve. The main control valve directs fluid to the lift and tilt cylinders and the auxiliary function.

Service Information Document Title: Implement descripton

Function Group: pump, 913

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Implement pump, descripton The implement pump is a gear pump and is mounted at the end of the transmission pumps forming a unit. The transmission pump shaft drives the implement pump at engine crankshaft speed.

On MC90BHF and MC110BHF the implement pump is mounted on the PTO on the right side of the engine and is driven by a splined shaft in the engine.

Engine speed determines the pump output.

The location of the implement pump is shown in, 913 Hydraulic pumps, overview.

The pump gets fluid from the tank and pumps it to the main control valve. The main control valve directs fluid to the lift and tilt cylinders and the auxiliary function.

For more information regarding gear pumps, see 442 Gear pump, description

Service Information Document Title: Servo system, description

Function Group: 914

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Servo system, description Pilot controls Hydrostatic transmission Always read the descriptions together with an hydraulic diagram.

Figure 1

1

Charge outlet

4

MA9113

7

Connection to servo piston

2

Accumulator

5

Accumulator solenoid valve

8

Connection, auxiliary function

3

Check valve

6

Hydraulic pilot control valve

9

Connection, hydraulics, lever

working

The transmission is operated by the left pilot control handle.

The fluid flows from the charge pump to a back pressure valve and on to the accumulator.

When MA9113 is activated the accumulator valve opens and servo pressure enters the left and right pilot control lever. From the left right pilot control lever the servo pressure goes via a valve block and a cross-over valve into the transmission pump.

The servo pressure affects directly to the stroking piston which change angle on the swashplate.

Pilot control lever The pilot control lever has four control spools that are connected to a cross–over valve.

By moving the pilot control lever the spools actuate, and via the cross-over valve the correct amount of servo pressure is distributed to the servo pistons on the transmission pump. For more information regarding the control lever, see 915 Control levers, description.

Accumulator The accumulator maintains a stable servo system pressure to get higher response on the pilot control lever. In event of power loss, the accumulator also supplies enough pressure to the lift and tilt spools in the main control valve to enable the operator to lower the loader arm. A connection located on the servo line between the check valve and the accumulator connects the servo line to the electrical operated auxiliary valve. This line is needed to relieve pressure in the auxiliary lines when disconnecting auxiliary attachments.

Service Information Document Title: Servo system, description

Function Group: 914

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Servo system, description Pilot controls Working hydraulics Always read the descriptions together with an hydraulic diagram.

Figure 1

1

Charge outlet

5

Accumulator valve

9

Auxiliary spool

2

Accumulator

6

Pilot control valve

10

MA9111

3

Check valve

7

Lift spool

11

MA9112

4

MA9113, hydraulic lock

8

Tilt spool

The working hydraulics is operated by the right pilot control lever.

Fluid goes from the charge pump via a check valve to the accumulator. When the hydraulic lockout solenoid MA9113 is activated the hydraulic lockout valve opens and servo pressure enters the left and right pilot control levers. From the right pilot control lever the servo pressure goes to the main control valve.

Pilot control lever The pilot control lever has four valves, two valves are connected to the lift spool and two valves are connected to the tilt spool. When operating the pilot control lever the valves open and servo pressure actuates the lift or tilt spool. The return

fluid from the opposite side of the spool goes via the pilot control lever valve back to tank.

When moving the pilot control lever fully forward the float function on the lift spool activates. The pilot control lever engages in float position by MA9108 and disengages by pulling the pilot control lever backwards.

Accumulator The accumulator maintains a stable servo system pressure to get higher response on the pilot control lever. In event of power loss, the accumulator also supplies enough pressure to the lift and tilt spools in the main control valve to enable the operator to lower the loader arm. A connection located on the servo line between the check valve and the accumulator connects the servo line to the electrical operated auxiliary valve. This line is needed to relieve pressure in the auxiliary lines when disconnecting auxiliary attachments.

Service Information Document Title: Servo pressure, check

Function Group: 914

Information Type: Service Information

Profile: SSL, MC80B [GB] Go back to Index Page

Servo pressure, check Op nbr 914-057 11666051 Pressure gauge 14290266 Hose

Output pressure Control lever valve 1. Put the machine in Service position 1, see 191 Service position 1.

2. Release any trapped hydraulic pressure, see 900 Hydraulic system, relieve pressure.

3. Clean the area around the hydraulic connection.

WARNING Loosen carefully. There may be hot/high-pressure oil in the line.

4. Disconnect the servo hose concerned, and plug the transmission pump connection.

Figure 1

1.

Test location

5. Connect a T-coupling to the servo hose and plug the opposite connection.

6. Install 14290266 Hose and 11666051 Pressure gauge, to the T–coupling.

7. Start the engine and increase to full throttle.

Date: 2014/3/19

Read the pressure gauge.

For correct pressure value, see 914 Servo system, description.

If the pressure is lower than specification the failure can be located on the valve block on the pilot control lever, see 915 Control lever, adjustment.

If the pressure in within range continue the test.

8. Stop the engine.

Servo rod, transmission pump 9. Release any trapped hydraulic pressure, see 900 Hydraulic system, relieve pressure.

WARNING Risk of high-pressure oil.

10. Remove the plug from the transmission pump.

11. Remove the plug from the T-coupling.

12. Install the T-coupling, pressure gauge and servo hose to the transmission pump.

13. Start the engine and increase to full throttle.

Read the pressure gauge.

For correct pressure value, see Charge pressure specification in 900 Hydraulic pressure, specifications or 900 Hydraulic pressure, specifications.

If the pressure is lower than specification the transmission pump servo rod probably has internal leakage, and the transmission pump has to be replaced, see 442 Transmission pump, removing.

14. Remove the pressure gauge and the T–coupling from the test location.

15. Reconnect the servo hose to the transmission pump.

16. Lower the cab from the service position.

Service Information Document Title: Servo pressure, check

Function Group: 914

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Servo pressure, check Op nbr 914-057 14290266 Hose 11666051 Pressure gauge

This operation also includes required tools and times for applicable parts of the following operations: 191 Service position 1 900 Hydraulic system, relieve pressure

ď‚Ą ď‚Ą

From pump to control lever 1. Put the machine in service position 1, see 191 Service position 1.

2. Release any trapped hydraulic pressure, see 900 Hydraulic system, relieve pressure.

3. Clean the area around the hydraulic connection.

WARNING

4.

Loosen carefully. There may be hot/high-pressure oil in the line.

Disconnect and plug the hose at the test location, and install the pressure gauge.

Figure 1

1.

Test location, MG

5. Start the engine and increase to full throttle and read the pressure gauge. For correct pressure value, see 900 Hydraulic pressure, specifications.

If the measured pressure is not within specification, the reason can be the charge relief valve, see 440 Charge system pressure relief valve test, or a charge pump failure.

6. Release any trapped hydraulic pressure and remove the pressure gauge.

Service Information Document Title: Accumulator, checking

Function Group: 914

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Accumulator, checking This test is preformed from the operator's seat.

1.

2.

3.

4.

5.

6.

7.

8.

Lower the seat bar Start the engine.

Press the hydraulic lock out switch Raise the loader arm approximately 1 meter from the ground.

Turn off the engine.

Turn the key to ON position.

Press the hydraulic lock out switch Move the lift/tilt control handle fully forward It should now be possible to operate the lift function at least three times before the pressure from the accumulator gets to low and the lift function stops working If it is not possible the accumulator could be in poor condition and has to be replaced

The accumulator could also be tested by removing the accumulator and check the precharge pressure, see 527 Accumulator, checking (removed) .

Service Information Document Title: Servo pipe and replacing

Function Group: hose, 914

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Servo pipe and hose, replacing Op nbr 914-071 This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą ď‚Ą

191 Service position 1 915 Control lever, changing 1. Put the machine in service position 1, see 191 Service position 1.

2. Remove the control lever from the console, see 915 Control lever, changing 3. Untie the hoses and loosen the protection shield.

4. Disconnect the worn hose from the control handle valve.

Figure 1

1.

New hose

5. Connect the new hose to the worn hose.

6. Rout the new hose by pulling the old hose from the opposite end.

Figure 2

1.

Servo hoses

7. Disconnect the hoses from each other.

8. Disconnect the old hose from the transmission pump.

9. Connect the new hose to the pilot control handle valve and to the transmission pump.

10. Fit the protection shield around the hoses and tie up the hoses.

11. Fit the pilot control lever to the console, see 915 Control lever, changing 12. Lower the cab from the service position, see 191 Service position 1.

13. Bleed air from the system by, operating the control handle in different directions, with the engine at low idle, for a couple of minutes 14. Check the hydraulic oil level, refill if necessary

Service Information Document Title: Control levers, description

Function Group: 915

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Control levers, description Transmission (left lever)

Figure 1

1

Port 1

5

Control lever

9

Rod

2

Port 2

6

Spool

10

Valve block

3

Port 3

7

Control spring

11

Drilling

4

Port 4

8

Return spring

The pilot control levers contains a valve block (10) with four spools that are connected to a cross–over valve.

When the pilot control handle (5) is not actuated the control spools are held in neutral position by the return spring (7).

When moving the pilot control handle (5), the rod (9) pushes against the return springs (8) and the control spring (7). The control spring moves the control spool (6) downwards and closes the connection to tank (T). At the same time, the connection to the pressure port opens (P). Oil goes now via a drilling (11) and the cross-over valve, to the appropriate servo

piston in the transmission pump.

The pressure in the appropriate ports is proportional to the stroke of push rod/control spool and thus the position of the control lever.

Valve 1 (backward) and valve 3 (forward) on the control valve contain an additional spool. The additional spool makes the pressure curve raise softer in the first part of stroke, which results in less sensitive operation, and allows for finer control for most of the range. At the end of the range the pressure quickly increase to max.

Figure 2 Regulation diagrams A

Pressure (bar)

B

Push rod stroke (mm)

C

Deviation angle (°)

The cross–over valve contains two orifices connected to port 1 (backward) and port 3 (forward) on the valve block. These orifices makes the machine more smooth to operate.

Figure 3 Hydraulic diagram

Affected port

Lever movement

Port

Port 2

Right

G[T1]

Transmission pump section

Port 4

Left

F

Left side, rear (X3)

Port 1

Backward

C

Right side, front (X4)

Port 3

Forward

D

Left side, front (X4)

5

Orifice

E

Right side, rear (X3)

[T1]To back–up alarm switch Control lever, operation E.g.

Drive straight forward  

Pilot control lever forward, spool 3 actuates.

Oil goes through the orifice → shuttle valves → out to port C and D → in to port X4 and X4 on the transmission pump → oil moves the servo pistons.

Drive to the left    

When operating the pilot control lever obliquely forward/left, spool 3 and 2 actuates.

Oil goes from spool 3 through the orifice → shuttle valves → out to port C and D → in to port X4 and X4 on the transmission pump, → oil moves the servo piston.

At the same time oil from spool 2 goes through the orifice → shuttle valve → out to port F → in to port X 3 on the transmission pump.

Now both sides X3 and X4 on the front transmission pump are pressurized and the servo piston goes to neutral.

Drive straight backwards   

When operating the pilot control lever backwards, spool 1 actuates.

Oil goes through the orifice → shuttle valves → out to port F and E → in to port X3 and X3 on the transmission pump, → oil moves the servo pistons.

At the same time port G is pressurized. Port G is connected to the back–up alarm switch (SE3603)

Service Information Document Title: Control levers, description

Function Group: 915

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Control levers, description Working hydraulics (right lever)

Figure 1

1

Port 1, Loader arm raise

5

Control lever

9

2

Port 2, Bucket curl

6

Spool

10 Valve block

3

Port 3, Loader arm lower and Float function 7

Control spring

11 Drilling

4

Port 4, Bucket tilt

Return spring

8

Rod

The pilot control levers contains a four control spools valve block (10).

When the pilot control handle (5) is not actuated the control spools are held in neutral position by the return spring (8).

When moving the pilot control handle (5), the rod (9) pushes against the return spring (8) and the control spring (7). The control spring moves the control spool (6) downwards and closes the connection to tank (T). At the same time the connection to the pressure port opens (P). Oil goes now via a drilling (11) out to the appropriate main control valve function.

When operating the pilot control lever, servo oil is delivered from the control valve out to the lift and tilt functions on the main control valve. See table below: When the pilot control lever is fully stroked forward the loader arm spool moves to “float” position. The pilot control lever locks in float position by solenoid valve MA9108. The “float” function is interrupted by pulling the control lever backwards.

Figure 2

A. B. C.

Pressure (bar) Deviation angle (°) Prefeeling on port no. 3

The pressure in the appropriate ports is proportional to the stroke of push rod/control spool and thus the position of the control lever.

Figure 3

Affected port

Lever movement

Action

Port 2

Right

Bucket curl

Port 4

Left

Bucket tilt

Port 1

Backward

Loader arm raise

Port 3

Forward

Loader arm, lower

Port 3

Fully forward

Float function

Service Information Document Title: Control lever, changing

Function Group: 915

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Control lever, changing Pilot controls Left control handle Op nbr 915-002 This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą ď‚Ą

191 Service position 2 900 Hydraulic system, relieve pressure 1. Removal Put the machine in service position 2, see 191 Service position 2.

2. Relieve any trapped hydraulic pressure, see 900 Hydraulic system, relieve pressure.

3. Remove the left side cover

Figure 1

4. From underneath the cab, cut the ties holding the hydraulic hoses together.

Figure 2

1.

Backup-alarm connector to switch SW3603.

5. Disconnect the connector to back–up alarm switch, SW3603.

6. Remove the cable tie around the cover and pull the cover over the handle.

Figure 3

1.

2.

Cover Screw

7. Remove the screws holding the control handle to the console 8. Pull the assembly out of the console and cut the ties holding together the servo hoses.

Figure 4

1.

Wire harness

2.

3.

Hydraulic hose Back–up alarm monitor

9. Disconnect the electrical harness for the control buttons.

10. Remove the back–up alarm monitor from the control handle.

11. Mark, disconnect and plug the hydraulic hoses from the valve.

12. Installation Reconnect the hydraulic hoses to the control handle valve.

Figure 5

1.

2.

Servo hoses Electrical harness

Figure 6 Right lever, working hydraulics Right lever, working hydraulics Port

Function

Port

Function

Port 1

Loader arm raise

Port 3

Loader arm, lower and Float function

Port 2

Bucket curl

Port 4

Bucket tilt

Figure 7 Left lever, travel hydraulics Left lever, travel hydraulics Port

Function

Port

Function

Port C

Right side, front

Port F

Left side, rear

Port D

Left side, front

Port G

To back–up alarm sensor

Port E

Right side, rear

13. Reconnect the electrical harness to the control handle.

14. Reconnect the back–up alarm monitor.

15. Bundle up the hoses with a cable tie and fit the hose protection.

16. Carefully place the control handle assembly into the console. See that no hoses are twisted or bent.

Figure 8

17. Underneath the cab, pull straight, arrange and bundle the hoses and wires to avoid wear or squeeze damages. If needed raise the cab.

Figure 9

1.

Connector to back–up alarm switch SW3603.

18. Reconnect the connector to the back–up alarm switch SW3603.

19. Install the screws holding the control handle to console. Fit the cover and the cable tie.

Figure 10

1.

2.

Cover Screw

20. If any adjusting of the control handle is needed, see 915 Control lever, adjustment.

21. Fit the left side cover.

Figure 11

Service Information Document Title: Control lever, adjusting

Function Group: 915

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Control lever, adjusting Op nbr 915-003 1161053 Thread lock This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą

191 Service position 2

Pilot controls Left side 1. Put the machine in service position 2, see 191 Service position 2.

2. Remove the cable tie and pull up the cover .

3. With a feeler gauge, measure the distance between the cardan and the plunger.

For correct value, see 915 Control levers, specifications If the distance is too large or to small, adjust as follow:

Figure 1

1.

2.

3.

4.

Cover Feeler gauge Cardan Plunger

4. Remove the screws holding the control handle to the console

Figure 2

1.

Screws

5. Pull the assembly out of the console.

If necessary, remove the side panel and cut the ties holding together the servo hoses.

Figure 3

6. Disconnect the electrical harness.

7. Loosen the lock nut and remove the control handle by turning it counter clockwise .

Figure 4

1.

Lock nut

8. Remove the cardan with an allen key.

Figure 5

1.

2.

Allen key Cardan

9. Adjust the play by inserting or removing requisite amount of shims.

Figure 6

1.

2.

Cardan Shims

10. Apply thread locker Art. no. 1161053 on the end of the cardan thread.

Fit the cardan.

Tightening torque, see 915 Control levers, specifications

Figure 7

1.

Allen key

2.

Cardan

11. Fit the control handle to the cardan, but do not tighten the lock nut in this time.

12. Reconnect the electrical harness.

Figure 8

1.

Electrical harness

13. Tie up the hoses with cable ties and fit the hose protection. Put the control handle assembly into the console. See that no hoses are twisted or bend.

Fit the screws holding the control handle to the console.

Figure 9

1.

2.

Cover Lock nut

14. Before tightening the lock nut for the control handle, see that the handle has the correct angle. Tighten the lock nut.

15. Fit the cover and secure with cabel tie.

Service Information Document Title: Function Group: Self level valve, description 916

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Self level valve, description The self level valve function is to keep the angle (tilt) of the attachment bracket/bucket in the same position throughout the loader arm raise cycle. The self level valve contains two check valve assemblies, an adjustable orifice, a flow divider spool, and an unloading spool.

Figure 1 Self level valve PA Lift cylinder, rod end PD Tilt cylinder, base end PB Lift spool (lowering) PC Tilt cylinder, rod end 1

Loader arm check valve

5

Unloading spool

2

Adjustable orifice

6

Fixed orifice

3

Flow divider spool

7

Spring

4

Attachment tilt check valve

Valve operation The self level valve directs oil flow from the main control valve to the loader arm cylinders and attachment tilt cylinders. See, 916 Self level function, description

Service Information Document Title: Self level description

Function Group: function, 916

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Self level function, description

Figure 1 Extending tilt cylinder 1

Adjustable orifice

PA

Lift cylinder, rod end

X

Pressurized fluid

2

Fixed orifice

PB

Lift spool (lowering)

Y

Pressure free fluid

3

Flow divider spool

PC

Tilt cylinder, rod end

Z

Trapped fluid

4

Tilt check valve

PD

Tilt cylinder, base end

5

Unloading spool

6

Lift arm check valve

Extending tilt cylinder With the tilt spool in “NEUTRAL” and lift spool in the “RAISE” position, flow from the main control valve enters the base end of the loader arm cylinders.

As the loader arm cylinders extend, flow from the rod ports are directed to port A at the self level valve. Flow entering port A is able to pass through the adjustable orifice and through the fixed orifice in the flow divider spool.

The proportion of the flow split is determined by the size of the adjustable orifice. The rest of the fluid flows through the fixed orifice and out port B back to the main control valve and returns to the hydraulic tank.

The fluid that passes through the adjustable orifice, opens the tilt check valve and flows out port D to the base end of the attachment tilt cylinders. When the unloading spool is closed the pressure in the base end circuit raises up. When a certain pressure level is reached the unloading spool moves and the tilt cylinders can extend.

As the tilt cylinders extend, the fluid flow from the rod ports of the cylinders enters port C past the open unloading spool,

around the flow divider spool and out port B back to the main control valve and returns the fluid to the hydraulic tank.

NOTE! The purpose of the unloading spool is to prevent the attachment tilt cylinders from dumping during the self leveling cycle.

Figure 2 Fully extended tilt cylinder 1

Adjustable orifice

PA

Lift cylinder, rod end

X

Pressurized fluid

2

Fixed orifice

PB

Lift spool (lowering)

Y

Pressure free fluid

3

Flow divider spool

PC

Tilt cylinder, rod end

Z

Trapped fluid

4

Tilt check valve

PD

Tilt cylinder, base end

5

Unloading spool

6

Lift arm check valve

Fully extended tilt cylinder In case the attachment tilt cylinders reach the fully extended state during the self leveling cycle, the loader arm cylinders will continue to raise. When the attachment tilt cylinders are end of stroke, fluid that would normally flow out port D to the base end of the attachment tilt cylinders is trapped. Fluid pressure in the self level valve will cause the unloading spool to shift to the left and unload the flow back to tank. This prevents the loader arm cylinders from stopping during the raise function. In case the tilt is moved forward and the tilt cylinders are fully extended, the boom will stop.

Service Information Document Title: Function Group: Boom Suspension System, 916 description

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Boom Suspension System, description Option Boom suspension Boom suspension is an optional equipment to increase operator comfort and reduce mechanical stress for the lifting frame.

The system consist a suspension system for the lifting frame (the boom).

The system's main components are a piston accumulator, precharged with nitrogen gas, a check valve and an orifice. And two solenoids activated by a switch on the control panel.

The springing action is achieved by connecting MA4202 to the base end of the lifting cylinders so that the cylinder pressure "rests" against the accumulator while at the same time the rod end of the lifting cylinders is connected MA4201 to the hydraulic oil tank. When operating across uneven ground and the lifting arms are actuated by a "bouncing load", the lifting arms move vertically but the pressure variations are taken up (absorbed) by the accumulator. The orifice's diameter on the anti cavitation valve allows Self level to operate while boom suspension is active.

For more detailed information see; 990 Hydraulic diagram

Figure 1

1

Accumulator

4

Anti cavitation valve

7

Base end

2

MA4202

5

Orifice

8

Tank

3

MA4201

6

Symbol for Boom suspension

9

Rod end

Activating Boom suspension System The light on the switch is on when Boom suspension is activated, and off when deactivated.

Figure 2

Accumulators, charging The accumulator is charged even if the Boom suspension is disengaged to avoid the drop of the boom when Boom Suspension engaged.

Service Information Document Title: Function Group: Self level valve, removal 916 and installation

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Self level valve, removal and installation Op nbr 916-036 1. Put the machine in service position 1, see 191 Service position 1.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Relieve any hydraulic pressure.

2. Clean the area around the hydraulic fittings, tubes, and hoses.

Figure 1

1.

Self level valve

3. Tag and remove all hydraulic hoses from the self level valve assembly. Cap or plug all hoses and ports in the valve housing.

4. Remove the valve assembly from the loader.

NOTE! Replace hydraulic fittings that are damaged and replace all used O–rings with new ones.

5. Install the hydraulic fittings into the new valve body in the same ports and orient them the same as they were before removal.

6. Install the self level valve assembly.

7. Install the hydraulic hoses.

8. Lower the cab from the service position, see 191 Service position 1.

9. Bleed air from the system by activating the lift and tilt functions up and down.

Service Information Document Title: Function Group: Self level valve, adjustment 916

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Self level valve, adjustment Op nbr 916-037 Perform the adjustment with the hydraulic oil at operating temperature 40-60 °C (104–140 °F).

Increase the engine to full throttle. Raise the loader arm. As the loader arm raises, the attachment tilt cylinders should extend and keep the attachment levelled with the ground.

NOTE! When the loader arm is raised slowly, the self level function does not work.

1. Put the machine to service position 1, see 191 Service position 1

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 2. Remove the cap from the adjustment screw on the self level valve.

Figure 1

1.

2.

3.

Cap Adjustment screw Lock nut

3. Loosen the lock nut and adjust the set screw. When correct adjustment is attained, tighten the lock nut.  

If the attachment dumps, the setscrew needs to be adjusted clockwise.

One turn on the adjustment screw makes the tilt cylinder extending approx. 15 mm (0.59 in) shorter.

If the attachment curls, the setscrew needs to be adjusted counter clockwise.

One turn makes the tilt cylinder extending approx. 15 mm (0.59 in) longer.

4. Replace the cap on the adjustment screw.

5. Lower the cab, see 191 Service position 1.

6. Check the self level function.

Service Information Document Title: Self level valve, bypass

Function Group: 916

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Self level valve, bypass Op nbr 916-038 Bypass If the lift or tilt cylinders will not support a load, the self level valve could be out of adjustment. Check the self level valve function by following the instruction bellow.

1. Put the machine in service position 1, see 191 Service position 1.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Relieve any trapped hydraulic pressure, see 900 Hydraulic system, relieve pressure.

2. Clean area around the hydraulic fittings on the self level valve assembly.

3. Disconnect hydraulic hose (2) and (3) and connect them together. Tighten securely.

Figure 1

1.

2.

3.

4.

5.

Self level valve Lift cylinder, rod end Main control valve, lower function Tilt function, forward Tilt function, backward

4. Disconnect and plug hydraulic connection (4) from the self level valve.

NOTE! Use pressure safe plugs.

5. Disconnect and plug hydraulic connection (5).

NOTE! Use pressure safe plugs.

6. Cap all fittings on the self level valve.

7. Lower the cab from the service position, see 191 Service position 1.

8. Bleed air from the system by operating the lift and tilt functions up and down.

If the lift or tilt cylinders could not keep the load, the self level valve is not out of function.

If the lift or tilt cylinders can keep the load, the self level valve is out of function and should be replaced, see 916 Self level valve, removal and installation.

Service Information Document Title: Hydraulic quick description

Function Group: attach, 924

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic quick attach, description The machine can be equipped with a optional hydraulic quick attach, where the attachments are locked with the aid of hydraulic cylinders (attachment lock).

The switch SW9114 activates both hydraulic valves MA9109 to open. Then the hydraulic flow is ordered by the right control lever from the male side of the auxiliary line for locking.

See also complete hydraulic diagram: 990 Hydraulic diagram and software description: 3012 9F9002, hydraulic quick attach

Figure 1 Hydraulic quick attach, Operator's view 1.

2.

3.

Indicator plate for lock pin Cylinder MA9109

Figure 2 Front view 1.

Lock pins

Service Information Document Title: Function Group: Attachment, installation/ 924 removal

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Attachment, installation/removal Attachment installation If the attachment requires connecting additional equipment beyond the attachment bracket, hydraulic couplings or electrical controls refer to that attachment operators manual.

WARNING Locking pins must be in full contact with the lower edge of the slot in the attachment. Locking levers must be fully lowered. The attachment could come loose from the attachment bracket if the slot on the attachment is excessively worn or the attachment mount is not properly aligned. Failure to secure locking pins in the attachment slots could allow the attachment to come off and cause death or serious injury.

1.

Raise both locking levers straight up.

Figure 1 2.

Operate the machine so that the mechanical attachment bracket hooks on to the attachment.

3.

Figure 2 Attachment bracket hooks on to the attachment Lift, tilt backwards and lock the attachment bracket locking levers.

Figure 3 Locking levers in locked position

Figure 4 Machine tilted by pushing the attachment to the ground

NOTICE Check that the attachment is locked securely by pressing the front edge of the attachment against the ground so that the machine's front end is raised slightly.

Attachment removal If the attachment requires disconnecting additional equipment beyond the attachment bracket, hydraulic couplings or electrical controls, refer to that attachment operators manual.

1.

2.

3.

4.

The attachment should be on firm level ground.

Disconnect any hydraulic couplings.

Fully raise both locking levers until the locking pins are retracted into the mechanical attachment bracket (disengaged position) Lower the loader arm and tilt forward so that the attachment falls off the mechanical attachment bracket.

Service Information Document Title: Attachment removal

Function Group: bracket, 924

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Attachment bracket, removal Op nbr 924-028 1. Remove any attachment from the attachment bracket.

2. Put the machine in service position 2, see 191 Service position 2.

3. Raise the loader arm slightly and place blocking under the bottom of the attachment bracket.

Figure 1 Attachment bracket support 1.

2.

Blocking Attachment bracket

4. Tilt the attachment bracket forward until the front face rests level with the ground.

5. Lower the loader arm until the attachment bracket is supported by the blocking.

6. Shut the engine OFF. 7. Turn the ignition key to the RUN position. With the seat restraint bar lowered fully, push the lift/tilt lockout switch on the instrument panel.

8. Depress the front and rear of both foot pedals to relieve any pressure in the loader arm hydraulic system.

9. Remove the capscrew, locknut, pin and any shims attaching the rod end of the attachment tilt cylinders to the attachment bracket.

NOTE! Tag and note the location and quantity of shims that may be used for proper installation.

Figure 2 Model MC80B/MC90B/MC110B shown, other models similar 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Capscrew Locknut Pin Shims Attachment bracket Capscrew Locknut Pin Loader arm Shim

10. Remove the capscrew, locknut, pin and any shims attaching the loader arms to the attachment bracket. Tag and catch any shims that may be used for proper installation.

NOTE! Tag and the location and quantity of shims that may be used for proper installation.

Service Information Document Title: Attachment installation

Function Group: bracket, 924

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Attachment bracket, installation Op nbr 924-029 NOTE! Also check the bushings at the tilt cylinders and the loader arms. Replace if necessary.

1. Put the machine in service position 2 see, 191 Service position 2 2. Position the attachment bracket on blocking in front of the loader, and align both loader arm pivot pin holes with the corresponding holes in the frame.

Figure 1 Attachment bracket frame installation 1.

2.

3.

Attachment bracket Blocking Corresponding holes

3. Install the shims as required and pins that attach the attachment bracket to the loader arm.

NOTE! Place the shims as required to center the frame to the loader arm, and maintain a maximum clearance of 1.5 mm (0.06") between the components.

NOTE! Be careful not to damage the bushings.

Figure 2 Attachment bracket shimming 1.

2.

3.

4.

5.

6.

7.

Attachment bracket Loader arm Pivot pin shims Pin Capscrew Locknut Attachment tilt pivot pin grease fittings

4. Fit the capscrew trough the pin collar.

Tightening torque:60 Nm (44.3 lb ft) 5. Fit the locknut to the capscrew.

Tightening torque: 60 Nm (44.3 lb ft) 6. Using multi-purpose lithium based grease, grease both loader arm pivot pin grease fittings.

7. Install the shims as required and pins that attach the rod end of the attachment tilt cylinder to the attachment bracket frame.

NOTE! Place the shims as required to center the tilt cylinders to the attachment bracket, and maintain a maximum clearance of 1.5 mm (0.06") between the components.

Figure 3 Attachment tilt cylinder (rod end) shimming 1.

2.

3.

4.

5.

6.

Attachment bracket Pivot pin shims Tilt cylinder Pin Capscrew Lock nut

8. Fit the capscrew trough the pin collar.

Tightening torque: 60 Nm (44.3 lb ft) 9. Fit the locknuts to the capscrews.

Tightening torque: 60 Nm (44.3 lb ft) 10. Grease both tilt cylinder pivot pin grease fittings.

Service Information Document Title: Locking lever inspection

and

Function Group: pin, 924

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Locking lever and pin, inspection NOTE! The attachment bracket assembly DOES NOT have to be removed from the machine for inspection.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remove the bolt, washer, spring and lever handle from the attachment bracket.

Remove the screw that secures the guide and spring to the link.

Drive the spring pin out of the link and pin from the front.

Clean all parts in a suitable solvent before inspection. Remove any paint chips from mating surfaces.

Inspect all parts for wear or damage. Replace if necessary.

Inspect all welds.

Grease and insert the pin into its bore in the attachment bracket frame, aligning the tapered face toward the rear of the frame.

Install the link onto the pin and secure by driving the spring pin from the rear of the frame through both pin holes.

Continue driving the pin, until it engages the slot in the face of the attachment bracket frame.

Insert the screw through the guide and spring, and into the link. Align the lever pivot on the guide toward the rear of the frame.

Position the lever on the pivot on the frame and engage the guide to the lever.

Install the bolt, flat washer and spring through the lever handle into frame.

Tightening torque: 100 Âą25 Nm (74 Âą18.5 lbf ft) Using multi-purpose lithium based grease; grease both attachment bracket lock pin grease fittings.

Service Information Document Title: Hydraulic description

Function Group: cylinders, 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Hydraulic cylinders, description Description The loader contains two lift and two tilt cylinders. Each cylinder is double-acting and consists of a rod inside of a barrel that is extended or retracted by hydraulic system fluid pressure.

Operation When a function is activated, the main control valve directs hydraulic fluid to the rod or base end of the pistons in each cylinder pair, extending or retracting the rods.

Service Information Document Title: Lift lockout description

Function Group: function, 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Lift lockout function, description Valve description The lift lockout solenoid valve is a component of the lift/tilt lockout system, and is located either on the left side, inside the transmission compartment, or the right side in the engine compartment depending on machine model.

Figure 1 Lift lockout solenoid and valve 1.

2.

Lift lockout valve Solenoid MA9101

Figure 2

The valve consists of a solenoid operated cartridges that allow hydraulic fluid to flow from the lift cylinder base end, when certain operating conditions exist.

Valve operation The lift lockout valve solenoid is normally closed, and will not allow fluid to flow in the lift circuit. When the ignition key is in the RUN position, the seat bar lowered and the lift/tilt lockout switch momentarily depressed, the lift lockout solenoid becomes energized. Fluid is allowed to flow to and from the main control valve to both loader arm cylinders.

For more information regarding the lift lockout function, see 366 Lift and tilt lockout functions, description.

Service Information Document Title: Lift cylinder, removing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Lift cylinder, removing MC80B, MC90B, MC110B Op nbr 945-018 If your machine has an enclosed cab and/or front door assembly, remove the door.

1. Put the machine in service position 2, see 191 Service position 2.

2. Park the machine on a level surface with the loader arm approximately 20 mm (0.79 in) from the rubber bumper.

Place a suitable block under the attachment bracket.

Figure 1 X = Approximately 20 mm (0.79 in) 1.

2.

Loader arm Rubber bumper

3. Turn the ignition key to the RUN position and press the lift/tilt lockout switch. Relieve the pressure in the lift cylinders. Turn the ignition key to the OFF position.

4. Remove the two nuts and washers at the rear corners inside the cab.

5. Grasp both handholds at the front of the cab and tilt the cab forward until it locks securely.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 6. Clean the area on the lift cylinder where the hydraulic hoses connect to the base end and rod end.

7. Tag, remove and plug the hydraulic connections to the cylinder.

8. Secure the cylinder being removed to prevent the cylinder from falling while the pivot pins are removed.

Weight: 27 kg (4.4 lb)

Figure 2

9. Remove the rod end pivot pin capscrew and locknut. Record the location and catch any shims that might be used for proper installation.

Figure 3 Rod end mounting hardware 1.

2.

Rod end pivot pin capscrew Locknut

NOTE! The rod end pivot pin of the left cylinder is the pivot point for the loader arm safety support. Before removing the left rod end pivot pin, ensure that the loader arm safety support is secured in the normal operating position on the loader arm by the safety support pin.

10. Use a brass punch and a hammer to remove the rod end pivot pin. From the outside drive the pivot pin into the compartment. Record the location and catch any shims that may be used for proper installation

Figure 4

11. Remove the capscrew and locknut securing the base end of the lift cylinder to the frame.

Figure 5

1.

2.

3.

4.

Capscrew Locknut Lift cylinder Base end pivot pin

12. From the inside of the engine compartment drive the pivot pin through the frame. If necessary, remove the muffler.

Record the location and catch any shims that might be used for proper installation.

13. Remove the lift cylinder from the machine.

14. Thoroughly clean the lift cylinder using a suitable solvent and dry with a clean rag.

Service Information Document Title: Lift cylinder, removing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Lift cylinder, removing MC80B, MC90B, MC110B Op nbr 945-018 1. Park the machine in service position 2, see 191 Service position 2.

2. Park the machine on a level surface with the loader arm approximately 20 mm (0.79 in) from the rubber bumper.

Place a suitable block under the attachment bracket.

Figure 1 X = Approximately 20 mm (0.79 in) 1.

2.

Loader arm Rubber bumper

3. Turn the ignition key to the RUN position and press the lift/tilt lockout switch. Relieve the pressure in the lift cylinders. Turn the ignition key to the OFF position.

4. Remove the two nuts and washers at the rear corners inside the cab.

5. Grasp both hand holds at the front of the cab and tilt the cab forward until it locks securely.

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 6. Clean the area on the lift cylinder where the hydraulic hoses connect to the base end and rod end.

7. Tag, remove and plug the hydraulic connections to the cylinder.

Figure 2

8. Secure the cylinder being removed to prevent the cylinder from falling while the pivot pins are removed.

Weight: 25 kg (55 lb)

Figure 3

9. Remove the base end pivot pin capscrew and locknut.

Figure 4

10. Use a brass punch and a hammer to remove the base end pivot pin from the inside of the engine compartment side. Record the location and catch any shims that might be used for proper installation.

Figure 5 NOTE! The rod end pivot pin of the left cylinder is the pivot point for the loader arm safety support. Before removing the left rod end pivot pin, ensure that the loader arm safety support is secured in the normal operating position on the loader arm by the safety support pin.

11. Remove the capscrew and locknut securing the rod end of the lift cylinder to the frame. Use a crow bar to drive the pivot pin through the frame. Record the location and catch any shims that might be used for proper installation.

Figure 6

12. Remove the lift cylinder from the machine. Weight: 25 kg (55 lb)

Service Information Document Title: Lift cylinder repacking

Function Group: removed, 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Lift cylinder removed, repacking Op nbr 945-006 1. Use a suitable container to catch the oil from inside of the lift cylinder. Tip the cylinder over and drain the oil from the rod end port and the base end port.

NOTE! Take care of the oil in a environmentally safe way.

2. Secure the base end of cylinder in a vise and support rod end.

3. Place a suitable container under the cylinder to catch any oil spillage.

4. Remove the set screw from the head gland cap. Remove and discard the old nylon patch beneath the set screw.

5. Unscrew the head gland cap, use a large chain wrench or an other suitable tool.

Figure 1

1.

Head gland cap setscrew

6. Slide rod assembly from barrel assembly.

NOTE! Make sure that the surface of the rod end and barrel does not get damaged.

Cylinder piston, reconditioning 7. Secure trunnion end of the rod in a vise and support the piston end of the assembly.

8. Remove the locknut. The thread locker often leaves a white, powdery residue, which must be removed by brushing with a wire brush prior to reassemble.

Figure 2

9. Slide piston off rod.

10. Slide the spacer off rod.

11. Slide gland head and head gland cap off rod.

12. Remove square section seal, square ring, small o-ring and wear band from the piston and discard.

Figure 3

1.

2.

3.

4.

Wear band Square section seal Square ring O-ring

13. Remove O-ring, back-up ring, rod wiper, and deep Z seal from the gland head and discard.

Figure 4

1.

2.

3.

4.

Rod wiper Z seal O-ring Back-up ring

NOTE! Change all damage and worn out parts If the barrel is damaged, the entire cylinder assembly will need to be replaced.

14. Thoroughly clean and dry all metal parts with a suitable solvent.

15. Clean and inspect rod for scratches, dents, flat spots, damaged threads, and other damage.

16. Clean and inspect piston, gland head and rod for damage. Replace if needed.

Assembling 17. Grease all sealings and o-rings with vaseline before assembling.

18. Install new o-ring, back-up ring, rod wiper, and deep Z seal to the gland head and slide on the head gland cap and gland head on the rod.

19. Slide on the spacer to the rod.

20. Install square section seal, square ring, small o-ring and wear band to the piston.

21. Slide on the piston to the rod and install the locknut. For tightening torque see 945 Tilt cylinder, specification 22. Insert the rod firmly into the barrel, make sure that the seals doesn't get damaged.

23. Install the gland head and tighten the setscrew use Locking fluid strong, for tightening torque see 945 Tilt cylinder, specification

Service Information Document Title: Lift cylinder, installing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Lift cylinder, installing MC80B, MC90B, MC110B Op nbr 945-019 NOTE! DO NOT apply any type of lubricant to the cylinder pins during installation procedures that follow. Cylinder bushings are impregnated with a special lubricant, and DO NOT require additional lubrication.

1. Position the cylinder on the machine.

2.

Carefully install the base end pivot pin from the outside using the shims removed earlier.

NOTE! Place the shims as required to center the lift cylinder to the frame, and maintain a maximum clearance of 1.5 mm (0.06") between the components.

Figure 1

1.

2.

3.

4.

Capscrew Locknut Lift cylinder Base end pivot pin

3. Insert the capscrew from the top down and secure in place with a locknut. Tighten securely.

4. Align the cylinder rod end with pivot pin holes on loader arm.

Figure 2

1.

2.

3.

4.

5.

Cylinder rod end Loader arm safety support arm Pivot pin Capscrew Locknut

5. Carefully install the pivot pin from the outside using the shims removed earlier.

NOTE! Place the shims as required to center the lift cylinder to the loader arm, and maintain a maximum clearance of 1.5 mm (0.06") between the components.

6. Insert the capscrew from the top down and secure in place with a locknut. Tighten securely.

NOTE! The loader arm safety support arm hinges on the left cylinder rod end pivot pin. Ensure that the hardware removed during “Cylinder Removal” is replaced, and that the safety support moves freely once the rod end pivot pin is installed and secured.

7. Install hydraulic fittings and hoses in cylinder ports. Tighten securely.

8. Bleed air from the system by raising and lowering the loader arm five times, without running the cylinders to their end–positions.

If your machine is equipped with a front door, reinstall the door.

Service Information Document Title: Lift cylinder, installing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Lift cylinder, installing MC80B, MC90B, MC110B Op nbr 945-019 NOTE! DO NOT apply any type of lubricant to the cylinder pins during installation procedures that follow. Cylinder bushings are impregnated with a special lubricant, and DO NOT require additional lubrication.

1. Position the cylinder on the machine.

2.

Carefully install the base end pivot pin from the outside using the shims removed earlier.

NOTE! Place the shims as required to center the lift cylinder to the frame.

3. Insert the capscrew from the top down and secure in place with a locknut. Tighten securely.

Figure 1

4. Align the cylinder rod end with pivot pin holes on loader arm.

5. Carefully install the pivot pin from the outside using the shims removed earlier.

6. Secure pivot pin with the cap screw and the lock nut.

NOTE! The loader arm safety support arm hinges on the left cylinder rod end pivot pin. Ensure that the hardware removed during “Cylinder Removal� is replaced, and that the safety support moves freely once the rod end pivot pin is installed and secured.

7. Install hydraulic fittings and hoses in cylinder ports. Tighten securely.

Figure 2

8. Bleed air from the system by raising and lowering the loader arm five times, without running the cylinders to their end–positions.

Service Information Document Title: Tilt cylinder, removing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Tilt cylinder, removing MC80B, MC90B, MC110B Op nbr 945-021 1. Put the machine in service position 2, see 191 Service position 2.

2. Raise the loader arm slightly and place blocking under the bottom of the attachment bracket frame.

Figure 1

1.

2.

Block Front face

3. Tilt the attachment bracket forward until the front face of the frame rests level with the ground and lower the loader arms until the rear of the attachment bracket frame is supported by the blocking.

4. Shut the engine OFF. Turn the ignition key to the RUN position. With the seat restraint bar lowered fully, push the lift/tilt lockout switch on the instrument panel.

5. Relieve any pressure in the loader arm hydraulic system. Turn the key to the OFF position.

NOTE! Be sure the hydraulic port areas are free from dirt and debris before disconnecting hydraulic fittings.

6. Disconnect the hydraulic hoses from the rod and base end ports of both cylinders. Plug or cap the hoses and cylinder ports.

NOTE! Note and record the location and quantity of shims. Reinstall the shims in the same location and quantity during assembly later.

7. Remove the locknut and capscrew from the rod– and base end of the cylinder.

Figure 2

1.

2.

3.

4.

5.

6.

7.

Capscrew Locknut Pin Shims Rod end Attachment bracket Lubrication point

8. Drive rod end pivot pin from the attachment bracket. Catch any shims that might be used for proper installation.

9. Drive base end pivot pin from the loader arm. Catch any shims that might be used for proper installation.

10. Remove tilt cylinder from loader arm.

Service Information Document Title: Tilt cylinder, removing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Tilt cylinder, removing MC80B, MC90B, MC110B Op nbr 945-021 1. Park the machine in service position 2, see 191 Service position 2.

2. Raise the loader arm slightly and place blocking under the bottom of the attachment bracket frame.

Figure 1

1.

2.

Block Front face

3. Tilt the attachment bracket forward until the front face of the frame rests level with the ground and lower the loader arms until the rear of the attachment bracket frame is supported by the blocking.

4. Shut the engine OFF. Turn the ignition key to the RUN position. With the seat restraint bar lowered fully, push the lift/tilt lockout switch on the instrument panel.

5. Relieve any pressure in the loader arm hydraulic system. Turn the key to the OFF position.

NOTE! Be sure the hydraulic port areas are free from dirt and debris before disconnecting hydraulic fittings.

6. Disconnect the hydraulic hoses from the tilt cylinder. Plug or cap the hoses and cylinder ports.

Figure 2

1.

Hoses

NOTE! Note and record the location and quantity of shims. Reinstall the shims in the same location and quantity during assembly later.

7. Remove the locknut and capscrew from the rod– and base end of the cylinder.

Figure 3

1.

Pivot pin

8. Pull out the pivot pin from the attachment bracket. Catch any shims that might be used for proper installation.

9. Remove tilt cylinder from loader arm Weight: 20 kg (44 lb).

Service Information Document Title: Tilt cylinder repacking

Function Group: removed, 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Tilt cylinder removed, repacking Op nbr 945-010

Cylinder, dismantling NOTE! Place a vessel under the cylinder for the remaining oil.

1. Place the cylinder in a vice and make sure it is steady.

2. Loosen and remove the cap setscrew on the gland cap. Use a hook spanner to remove the gland head.

Figure 1

3. Pull out the rod from the barrel.

NOTE! Make sure that the surface of the rod end and barrel does not get damaged.

Cylinder piston, reconditioning 4. Place the rod in a vice.

5. Loosen and remove the lock nut for the piston. The thread locker often leaves a white, powdery residue, which must be removed by brushing with a wire brush prior to reassemble.

Figure 2

6. Remove the piston, o-ring and the gland head.

7. Change the wear band, o-ring, square section seal and the square ring Gland head NOTE! The side of the Z seal 8. Change the wear band (6), o-ring (7), back up ring (5), o-ring (4), Z seal (3), o-ring (2) and the rod wiper (1).

Figure 3

1.

2.

3.

4.

5.

6.

7.

Rod wiper O-ring Z-seal O-ring Back up ring Wear band O-ring

NOTE! Grease the o-rings with vaseline.

Rod, assembling 9. Coat the rod with a light film of clean hydraulic system oil and slide on the gland head on the rod.

10. Put some plastic tape over the threads before the o-ring is assembled. Slide on the o-ring firmly and remove the

plastic tape.

11. Slide on the piston on the rod.

12. Assembly the lock nut use locking fluid strong, for tightening torque see: 945 Tilt cylinder, specification 13. Insert the rod firmly into the barrel, make sure that the seals doesn't get damaged.

14. Install the gland head and tighten the setscrew use locking fluid strong, for tightening torque see: 945 Tilt cylinder, specification

Service Information Document Title: Tilt cylinder, installing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Tilt cylinder, installing MC80B, MC90B, MC110B Op nbr 945-022 NOTE! DO NOT apply any type of lubricant to the base end cylinder pins. Cylinder bushings are impregnated with a special lubricant, and DO NOT require additional lubrication.

1. Align cylinder ends with pivot pin holes on loader arm and attachment bracket.

2. Carefully push the pin in (placing shims as required) as far as possible with your hands and make sure pin is going in straight to avoid damage to bushing seals.

NOTE! Place the shims as required to center the tilt cylinder. Maintain a maximum clearance of 1.5 mm (0.06") between the components.

Figure 1

1.

2.

3.

4.

5.

Capscrew Locknut Pin Shims Rod end

6.

7.

Attachment bracket Lubrication point

3. Secure the base end of the cylinder.

4. Fit the capscrew trough the pin collar at the rod end on the cylinder.

Tightening torque: 60 Nm (44.3 lb ft) 5. Fit the locknuts to the capscrews.

Tightening torque: 60 Nm (44.3 lb ft) 6. Install hydraulic fittings and hoses in cylinder ports.

7. Bleed air from the system by raising and lowering the attachment five times, without running the cylinders to their end–positions.

Service Information Document Title: Tilt cylinder, installing

Function Group: 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Tilt cylinder, installing MC80B, MC90B, MC110B Op nbr 945-022 NOTE! DO NOT apply any type of lubricant to the base end cylinder pins. Cylinder bushings are impregnated with a special lubricant, and DO NOT require additional lubrication.

1. Align cylinder ends with pivot pin holes on loader arm and attachment bracket.

2. Carefully push the pin in (placing shims as required) as far as possible with your hands and make sure pin is going in straight to avoid damage to bushing seals.

NOTE! Place the shims as required to center the tilt cylinder. Maintain a maximum clearance of 1.5 mm (0.06") between the components.

Figure 1

1.

Pivot pin

3. Secure the base end of the cylinder.

4. Fit the capscrew trough the pin collar at the rod end on the cylinder.

5. Fit the locknuts to the capscrews.

6. Fit the pin and tighten the locknut

7. Install hydraulic fittings and hoses in cylinder ports.

Figure 2

1.

Hose fittings

8. Bleed air from the system by raising and lowering the attachment five times, without running the cylinders to their end–positions.

Service Information Document Title: Loader arm replacing

Function Group: bearing, 945

Information Type: Service Information

Profile: SSL, MC80B [GB] Go back to Index Page

Loader arm bearing, replacing Between Loader arm and attachment bracket Op nbr 945-040 9993714 Puller bolt 9993717 Quick nut 11667095 Drift plate 88830175 Pump 6999045 Drift plate 11666055 Jack

Attachment bracket, removal 1. Park the machine in Service position, see section 191 Service position 2 2. Support the loader arm with a lifting sling and a traverse hoist.

Date: 2014/3/19

Figure 1

1.

2.

3.

Traverse hoist Lifting sling Pallet

3. Place the attachment bracket on a pallet and use the pallet trolley to adjust height.

4. Remove the lock nut from the tilt cylinders rod end and loader arms end.

NOTE! Record the location and catch any shims that might be used for proper installation 5. Remove the pivot pins and shims from the tilt cylinders and loader arms.

Figure 2

1.

Pivot pins

6. Remove the attachment bracket Weight 70 kg (154 lb).

7. Place the new bearings in a freezer for about 15 minutes.

Bearings, removal 8. Press out the bearings from both loader arms. Use: 1.

2.

3.

4.

5.

6.

9993717 Quick nut 6999045 Drift plate Spacer sleeve Ă˜ mm 88830175 Pump 14360031 Puller bolt 11666055 Jack

Figure 3

1.

2.

3.

4.

5.

6.

Quick nut Drift plate Spacer sleeve Pump Jack Puller bolt

9. Check for cracks and clean the bearing race.

10. Grease the new bearings thoroughly.

11. Install the new bearings on both sides.

12. Install the attachment bracket.

13. Grease the pivot pins.

14. Install the pivot pins and the shims.

15. Install the cap screws and lock nuts for the tilt cylinders and loader arms.

Service Information Document Title: Loader arm replacing

Function Group: bearing, 945

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Loader arm bearing, replacing Rear side Op nbr 945-040 11666055 Jack 6999045 Drift plate 88830175 Pump 14360031 Puller bolt

1. Park the machine in Service position 2, see 191 Service position 2 2. Raise the loader arm slightly and place a blocking under the bottom of the attachment bracket frame.

Figure 1 NOTE! Make sure that the pressure in the hydraulic system is relieved.

3. Secure the loader arms with lifting slings supported by a traverse hoist.

Figure 2

1.

Lifting sling

4. Remove the pivot pin and lock screw from the end of the loader arms.

Figure 3

1.

2.

Pivot pin Lock screw

5. Tap out the pivot pin from the out side of the machine.

Figure 4 NOTE! Note and record the location and quantity of shims. Reinstall the shims in the same location and quantity during assembly later.

6. Lift the loader arm carefully, use the traverse hoist.

7. Check if there is any damage in the holes and the pivot pins.

NOTE! If necessary loosen, remove and plug the hydraulic hoses.

8. Press out the bearing on both sides of the machine with: 1.

2.

3.

4.

5.

14360030 Puller bolt 11666055 Jack 88830175 Pump Spacer sleeve Ă˜ mm 6999045 Drift plate

Figure 5

9. Clean the bearing race from dirt and check the bearing race for cracks.

Bearings, installing 10. Grease the new bearings thoroughly.

11. Install the bearings on both sides of the machine, use the tools from earlier steps.

12. Lower the loader arm back to its right position and install the schims.

13. Grease and install the pivot pins.

14. Install the lock screws for the pivot pins.

15. Grease the grease points on the loader arm.

16. Remove the lifting slings.

Service Information Document Title: Foot pedal cable, removal

Function Group: 950

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Foot pedal cable, removal Op nbr 950-001 1. Put the machine in service position, see 191 Service position 3.

2. Remove the floor plate and turn off the battery disconnect switch.

3. If the machine is equipped with front door (option):Remove the foot shield.

Figure 1

1.

Foot shield

NOTE! DO NOT reuse any elastic lock nuts. Discard any elastic lock nut(s) removed and replace with new.

4. Remove the protecting plate, see method 715 Protecting plate, removal 5. Loosen the four cap screws that attaches the pedal anchorage to the floor. Remove the pedal and the pedal anchorage.

Figure 2

1.

2.

Pedal anchorage Pedal

6. Remove the flat washer and cap screw connecting the ball joint to the foot pedal

Figure 3

1.

2.

3.

4.

5.

6.

7.

8.

Pin Hex jam nut Hex jam nut Washer Nut Ball joint Washer Cap screw

7. Remove the ball joint and the hex jam nuts from the cable.

8. Remove the foot pedal from the pedal anchorage by removing the retaining rings and washers on each side.

Remove the pedal pin mounted through the pedal anchorage

Figure 4

1.

2.

3.

4.

5.

6.

7.

Pedal anchorage Hex jam nut Washer Pin Washer Retaining ring Pedal

9. Tilt the cab, see 191 Service position 1 10. Remove the hose from the elbow fitting on the left side of the main control valve. Collect the oil in a suitable container. Cap the fitting and plug the hose end to prevent contamination from entering the valve and/or hydraulic system.

Figure 5

1.

2.

Cap screw Hose

11. Remove the three cap screws holding the valve to the crossmember, saving the hardware for reassemble. Carefully pull the valve, with the control cables attached, up and away from the crossmember and lay forward.

Figure 6

12. Loosen the sleeves from the lift spool and the tilt spool. Disconnect the cables from the spool.

13. Remove the cable from the machine.

Service Information Document Title: Foot pedal cable, removal

Function Group: 950

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Foot pedal cable, removal Op nbr 950-001 This operation also includes required tools and times for applicable parts of the following operations:   

191 Service position 3 900 Hydraulic system, relieve pressure 191 Service position 1 1. Park the machine in the service position See 191 Service position 3.

2. Relieve the pressure from the lift and tilt circuit, see 900 Hydraulic system, relieve pressure 3. Turn off the battery disconnect switch.

4. Remove the floor plate between the foot pedals.

5. Remove the battery hold down and the battery cables and remove the battery NOTE! DO NOT reuse any elastic lock nuts. Discard any elastic lock nut(s) removed and replace with new.

6. Remove the foot pedal assembly from the cab floor.

Figure 1

1.

Foot pedal assembly

7. Remove the cable form the foot pedal.

Figure 2

1.

2.

3.

4.

5.

6.

7.

8.

Bracket Jam nut Jam nut Spacer Nut Ball joint Washer Cap screw

8. Remove the ball joint from the foot pedal.

9. Remove the ball joint and the jam nuts from the cable.

10. Tilt the cab, see 191 Service position 1 11. Loosen but do not disconnect the hydraulic hose (tank) from the main control valve, turn it aside.

Figure 3

1.

2.

Hydraulic hose Connection to internal tube

3.

4.

PWM9123, connector PWM9123, solenoid valve

12. Disconnect the connector PWM9123 from the auxiliary solenoid.

13. Remove the solenoid valve PWM9123 from the main control valve.

14. Loosen the lock nut and sleeve from the spool. Disconnect the cable from the spool.

Figure 4

1.

2.

3.

Lock nut Sleeve Cable

15. Remove the cable from the machine.

Service Information Document Title: Foot pedal installation

Function Group: cable, 950

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Foot pedal cable, installation Op nbr 950-002 Inspect the cable for wear or damage. Replace if necessary.

1. Connect the new foot pedal cable to the spool.

2. Reinstall the valve by mounting the three cap screws holding the valve to the crossmember.

3. Remove the hose end plug and reinstall the hose to the elbow fitting on the left side of the main control valve.

Torque: see 030 Standard tightening torques

Figure 1

4. Tilt down the cab, see 191 Service position 1.

5. Mount the ball joint and the hex jam nuts on the cable 6. Mount the flat washer and cap screw connecting the ball joint to the foot pedal.

Figure 2 Foot pedal, cable mounting 1.

2.

3.

4.

5.

6.

7.

8.

Pin Hex jam nut Hex jam nut Washer Nut Ball joint Washer Cap screw

7. Reinstall the foot pedal by mounting the pedal pin through the pedal anchorage. Mount the retaining rings and washers on each side.

Figure 3 Foot pedal, mounting 1.

2.

3.

4.

5.

6.

7.

Pedal anchorage Hex jam nut Washer Pin Washer Retaining ring Pedal

8. Reinstall the foot pedal and the pedal anchorage. Tighten the four cap screws that attaches the anchorage to the floor.

9. Operate the foot pedal to ensure that the control valve spool moves fully into all of its operating positions.

Readjust if required.

Figure 4

1.

2.

18 ¹3° 142 mm (5.6 in)

10. Reinstall the protecting plate.

11. If the machine is equipped with front door (option); reinstall the foot shield.

12. Put the floor plate back.

Service Information Document Title: Foot pedal installation

Function Group: cable, 950

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Foot pedal cable, installation Op nbr 950-002 This operation also includes required tools and times for applicable parts of the following operations: ď‚Ą

191 Service position 1

Inspect the cable for wear or damage. Replace if necessary.

1. Rout the cable the same way as prior removal.

Figure 1

2. Connect the cable into the slot in the spool concerned. Fit the sleeve and tighten the jam nut.

Figure 2

1.

2.

3.

Lock nut Sleeve Cable

3. Fit the auxiliary solenoid valve PWM9123 to the main control valve

Figure 3

1.

2.

3.

4.

Hydraulic hose Connection, internal tube Connector PWM9123 Solenoid valve PWM9123

4. Connect the connector PWM9123 to the solenoid.

5. Connect the internal tubes to the main control valve.

6. Restore the hydraulic hose to its original position.

7. Tilt down the cab, see 191 Service position 1.

8. Fit the nuts, washers and ball joint to the cable.

9. Fit the cable to the foot pedal.

Figure 4

1.

2.

3.

4.

5.

6.

7.

8.

Bracket Jam nut Jam nut Washer Nut Ball joint Spacer Cap screw

10. Adjust the cable as in figure.

Figure 5

1.

2.

18 ¹3° 142 mm (5.6 in)

11. Fit the foot pedal console to the floor.

12. Fit the battery into the compartment.

13. Connect the battery cables to the battery and fit the battery hold down.

14. Fit the floor plate.

15. Connect the battery disconnection switch 16. Turn the key to on position 17. Operate the foot pedal to ensure that the control valve spool moves fully into all of its operating positions.

Readjust if required.

Service Information Document Title: Error codes, build-up

Function Group: 990

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Error codes, build-up Display unit The error codes shown on the display unit are built up from a character combination with the following appearance and meaning.

Figure 1 Example of error code "Fuel level sensor, high voltage" detected at 123.4 machine time hours Position 1 Indicates which type of component or function that has generated the error code. Abbreviations are found in the first 2-3 letters of the error codes.

HE

Heating coil

MA

Solenoid valve

PWM

Pulse width modulated valve

RE

Relay

SE

Sensor or monitor

SW

Switch

Positions 2a and 2b States component number where 2a signifies function group and 2b is a consecutive number within the function group.

Position 3 States FMI-code and based on SAE standard J1587. FMI means Failure Mode Identifier and states which type of error that has caused the error code.

0

Data valid but above normal operational range.

1

Data valid but below normal operational range.

2

Data erratic, intermittent or incorrect.

3

Abnormally high voltage or short-circuit to higher voltage.

Abbreviated in error code texts "high voltage"

4

Abnormally low voltage or short-circuit to lower voltage.

Abbreviated in error code texts "too low voltage"

5

Abnormally low current or open circuit.

Abbreviated in error code texts "too low current"

6

Abnormally high current or short-circuit to frame ground.

Abbreviated in error code texts "high current"

7

Mechanical system not responding properly.

Abbreviated in error code texts "mechanical error"

8

Abnormal frequency, pulse width or period.

9

Abnormal updating rate.

10

Abnormally wide variations.

11

Unidentifiable malfunction.

Abbreviated in error code texts "other error"

12

Defective unit or component.

13

Calibration value outside limits.

14

Special instructions.

15

Reserved for future use.

Service tool VCADS Pro The error codes in VCADS Pro are built up as follows.

Figure 2 Error code display in service tool VCADS Pro Position 1, MID

Indicates the control unit that generated the error code. Based on SAE standard J1587. 

MID means Message Identification Description (identification of control unit).

128

Engine control unit

187

Vehicle control unit

Position 2, PID, PPID, SID, PSID Indicates the component/parameter that generated the error code. Based on SAE standard J1587.   



PID means Parameter Identification Description (identification of parameter/value).

There is a unique number for each parameter.

PPID means Proprietary Parameter Identification Description (Volvo-unique identification of parameter/value). A Volvo-unique number for every parameter.

SID means Subsystem Identification Description (identification of component). The SID–number depends on from which control unit (MID) they are sent. Every control unit has its own number series for SID. The exceptions are SID– numbers 151–255 which are general for all systems.

PSID means Proprietary Subsystem Identification Description (Volvo-unique identification of component).

Position 3, FMI Indicates what type of problem has generated the error code.

Service Information Document Title: Function Group: Explanations to hydraulic 990 diagram

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB]

Explanations to hydraulic diagram Symbols Symbol

Explanation Line Servo line / Pilot line Line junction

Crossing lines not connecting

Outlet, plugged Quick-action coupling (e.g. checking point) Restriction Restriction, insignificantly viscosity-dependent Adjustable restriction

Reservoirs and accumulators Atmospheric (open) reservoir

Accumulator Filter Filter, strainer

Filter with magnetic element

Heat exchanger

Cooler without representation of lines for the coolant

Control devices Manual control by push button

Manual control by lever

Manual control by pedal

Mechanical control by spring, neutral position spring, return spring

Electromagnetic control (one winding)

Hydraulic pressure control

Hydraulic pressure control, two pressure levels

Control via hydraulic pressure drop

Pneumatic control

Control via pneumatic pressure drop

Sources of energy Combustion engine

Electric motor

Pumps

Hydraulic pump with fixed displacement and one direction of flow

Hydraulic pump with variable displacement and one direction of flow

Hydraulic pump with variable displacement and two directions of flow

Hydraulic pump with variable displacement, pressure controlled

Hydraulic pump with variable displacement, pressure controlled with pressure-compensated control

Motors Hydraulic motor with fixed displacement and one direction of flow

Hydraulic motor with fixed displacement and two directions of flow

Cylinders Single-acting cylinder with return stroke by spring

Double-acting cylinder with single piston rod (The piston end is called plus side and the piston rod end is called minus side)

Valves Non-return valve which requires very low opening pressure

Non-return valve which requires a certain opening pressure Shuttle valve

Pressure-limiting valve

Pressure-limiting valve with adjustable opening pressure

Pressure-reducing valve

Pressure-reducing valve with adjustable closing pressure

Pressure-reducing valve, pressure controlled

Three-position valve, lever-controlled and spring-centred

Lines parallel with the long sides of the valve symbol show that the valve can take up any position between its end positions (stepless movement) Shut-off valve / Breather valve

Application The symbols in a diagram show connections, flow paths and function of the components in the system, but does not show

the design of the components.

NOTE! In a hydraulic diagram the valve symbols are always drawn in neutral position.

Valve symbols The basic element of a valve symbol is a square box. One box is shown for each position that the moving part of a valve (spool or similar) can take up.

Figure 1 Valve symbol If the valve does not have fixed positions, but can be operated steplessly, this is shown with parallel lines along the valve symbol.

Figure 2 Valve symbol, steplessly controlled valve Internal flow paths and flow directions are drawn in the boxes. Line connections to the valve are drawn to the box that shows the valve position when other components are actuated according to the diagram.

Figure 3 Closed valve

Figure 4 Open valve Interpretation of valve symbols In a three-position valve the spool can be placed in three positions, which in the symbol are represented by one box for each position. The box that represents the intended position is drawn between the line connections, which means that the appropriate connecting paths in the valve are shown in the diagram.

The position in the diagram

Figure 5 Neutral position 1.

2.

Inlet Outlet

The spool is centred in neutral position by the springs. The inlet is connected to the outlet through the spool.

Imagined position for piston movement outwards

Figure 6 The piston rod is pressed out 1.

2.

Inlet Outlet

The spool is actuated with the lever so that the plus side of the cylinder is connected to the inlet at the same time as the minus side is connected to the tank.

Imagined position for piston movement inwards

Figure 7 The piston rod is pressed in 1.

2.

Inlet Outlet

The spool is actuated with the lever so that the minus side of the cylinder is connected to the inlet at the same time as the plus side is connected to the tank.

Service Information Document Title: Function Group: Hydraulic diagram, MC80B, 990 Mechanical controls

Information Type: Service Information

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic diagram, MC80B, Mechanical controls A

Female

B

Male

1

Tilt cylinder

2

Lift cylinder

3

Auxiliary hydraulics

4

Loader arm lockout valve

5

Main control valve MRV

6

PPV 7

Main relief valve

Charge/Implement pump Pressure priority valve

Transmission pump R1 – R4

Loop pressure relief valve

8

Right drive motor

9

Left drive motor

10

—

11

Main hydraulic system filter BPV1

Back pressure valve

12

Engine

13

Hydraulic tank

14

Self level valve (option)

15 – 20

—

21

PRV

Servo pressure reducing valve

22

CV

Check valve

23

Accumulator, servo pressure

MA9101

Lift lockout solenoid

MA9103

Tilt spool lockout solenoid

MA9104

Lift spool lockout solenoid

MA9111

Auxiliary solenoid

MA9112

Auxiliary solenoid

SE9102

Main hydraulic filter restriction monitor

For information about hydraulic pressure, see 900 Hydraulic pressure, specifications.

Date: 2014/3/19

Figure 1 Hydraulic diagram, MC80B

Service Information Document Title: Function Group: Hydraulic diagram, MC80B 990 and MC90B, Mechanical controls

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic diagram, MC80B and MC90B, Mechanical controls 1

Tilt cylinder

2

Lift cylinder

3

Auxiliary hydraulics A

Female

B

Male

4

Loader arm lockout valve

5

Main control valve MRV

Main relief valve

6

Implement pump

7

Transmission pump R1 – R4

Loop pressure relief valve

R5

Charge pressure relief valve

8

Right drive motor

9

Left drive motor

10

Charge pump

11

Main hydraulic system filter

12

Engine

13

Hydraulic tank

14

Self level valve (option)

15 – 22

—

23

Accumulator, servo pressure

24 – 26

—

27

Breather, cap hydraulic tank

28

Quick attach (option)

29

Boom suspension BSS (option)

30

Anti cavitation valve (option)

MA4201

BSS – solenoid (option)

PWM9123

Auxiliary solenoid

MA4202

BSS + solenoid (option)

PWM9124

Auxiliary solenoid

MA9101

Lift lockout solenoid

SE9101

Hydraulic fluid temperature, monitor

MA9103

Lift spool lockout solenoid

SE9102

Main hydraulic filter restriction monitor

MA9104

Tilt spool lockout solenoid

MA9109

Quick attach solenoids (option)

For information about hydraulic pressure, see 900 Hydraulic pressure, specifications.

Figure 1 Hydraulic diagram, MC80B, MC90B, Mechanical controls

Service Information Document Title: Function Group: Hydraulic diagram, MC80B, 990 Pilot controls

Information Type: Service Information

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic diagram, MC80B, Pilot controls A

Female

B

Male

1

Tilt cylinder

2

Lift cylinder

3

Auxiliary hydraulics

4

Loader arm lockout valve

5

Main control valve MRV

Main relief valve

6

Implement pump

7

Transmission pump R1 – R4

Loop pressure relief valve

8

Right drive motor

9

Left drive motor

10

Charge pump

11

Main hydraulic system filter

12

Engine

13

Hydraulic tank

14

Self level valve (option)

15 – 21

—

22

CV

23

Accumulator, hydraulic lockout valve (servo pressure)

24

Pilot control, transmission

25

Pilot control, working hydraulics

Check valve

MA9101

Lift lockout solenoid

MA9108

Float lock solenoid

MA9111

Auxiliary solenoid

MA9112

Auxiliary solenoid

MA9113

Pilot accumulator, lockout solenoid

SE9102

Main hydraulic filter restriction monitor

SW3603

Back–up alarm monitor

For information about hydraulic pressure, see 900 Hydraulic pressure, specifications.

Date: 2014/3/19

Figure 1 MC80B, Pilot controls

Service Information Document Title: Function Group: Hydraulic diagram, MC80B 990 and MC90B, Pilot controls

Information Type: Service Information

Date: 2014/3/19

Profile: SSL, MC80B [GB] Go back to Index Page

Hydraulic diagram, MC80B and MC90B, Pilot controls 1

Tilt cylinder

2

Lift cylinder

3

Auxiliary hydraulics A

Female

B

Male

4

Loader arm lockout valve

5

Main control valve MRV

Main relief valve

6

Implement pump

7

Transmission pump R1 – R4

Loop pressure relief valve

R5

Charge pressure relief valve

8

Right drive motor

9

Left drive motor

10

Charge pump

11

Main hydraulic system filter

12

Engine

13

Hydraulic tank

14

Self level valve (option)

15

Charge filter

16 – 22

—

23

Accumulator, hydraulic lockout valve (servo pressure)

24

Pilot control, transmission

25

Pilot control, working hydraulics

26

—

27

Breather, cap hydraulic tank

28

Quick attach (option)

29

Boom suspension BSS (option)

30

Anti cavitation valve (option)

MA4201

BSS – solenoid (option)

PWM9123

Auxiliary solenoid 1

MA4202

BSS + solenoid (option)

PWM9124

Auxiliary solenoid 2

MA9101

Lift lockout solenoid

SE9101

Hydraulic fluid temperature, monitor

MA9108

Float lock solenoid

SE9102

Main hydraulic filter restriction monitor

MA9109

Quick attach solenoid (option)

SW3603

Back–up alarm monitor

MA9113

Pilot accumulator lockout solenoids

For information about hydraulic pressures, see 900 Hydraulic pressure, specifications.

Figure 1 Hydraulic diagram, MC80B, MC90B, Pilot controls

Many thanks for your purchase.

Happy every day.

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