Kobelco COMPACT LOADER WITH ACCESSORIES SL65B Hydraulic Excavator WORKSHOP MANUAL – PDF DOWNLOAD

Description

Kobelco COMPACT LOADER WITH ACCESSORIES SL65B Hydraulic Excavator WORKSHOP MANUAL – PDF DOWNLOAD

DESCRIPTION:

Kobelco COMPACT LOADER WITH ACCESSORIES SL65B Hydraulic Excavator WORKSHOP MANUAL – PDF DOWNLOAD

TO THE READER

• This manual has been written for a skilled technician, in order to give him the information necessary to repair this machine.
• Read this manual carefully for correct information about repair procedures.
• For any question or comment, or in case you notice a mistake in this manual

ADDITIONAL REFERENCE MANUALS 

• In addition to this Workshop Manual, refer also to the following:
• Operation and maintenance instruction manual
• Spare parts catalog

DESCRIPTION OF THE COMPLETE WORKSHOP MANUAL

• The complete repair manual consists of one volume: SL35B-SL40B – Workshop Manual “Compact loader with accessories”

• “Compact loader with accessories” Workshop Manual contains the technical information necessary for machine/engine service and repair, service equipment, information on maintenance standards, remove and install procedures, disassembly and assembly procedures.

• The complete Workshop Manual for the compact loader with accessories model SL35B-SL40B consists of the following volume identified by print number as shown herebelow:

AVOID ACCIDENTS

• Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions.
• For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation.
• Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many thousand serious injuries each year. That rule is: Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION

• On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing.
• If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment

INTRODUCTION

• This service manual provides the technical information needed to properly service and maintain the Models SL35B andSL45B skid steers. Use it in conjunction with the operator’s manual which is supplied with the skid steer. Keep both manuals available for ready reference. The SL35B andSL45B have many similarities with the major differences being engine horsepower and lifting capacity. Whenever working on FIAT-HITACHI equipment, left and right sides of the machine are determined by standing behind the unit, looking in the direction of travel.
• The easiest and least time-consuming removal, disassembly, and reassembly procedures are detailed in the manual. Modifying these procedures is not recommended. FIAT-HITACHI skid steers are designed with emphasis on safety for operator protection. However, careless and negligent operation can still result in serious injury to persons or damage to property.
• Be sure to read and follow all safety instructions in this manual. Your FIAT-HITACHI dealer is interested in your obtaining the most from your investment and will be glad to answer any questions you may have about your skid steer.
• When major service is required, your dealer’s staff of trained service technicians is ready to serve you. When in need of parts, always order genuine FIATHITACHI service parts from your FIAT-HITACHI dealer.
• Be prepared to give your dealer the model and serial number of the engine and skid steer (the location of these numbers is described later in this section). Record the serial numbers here. Skid Steer Model Skid Steer Serial Number Engine Model Engine Serial Number

CAUTION

This symbol is used throughout this book whenever your own personal safety is involved. Take time to be careful!

ABOUT IMPROVEMENTS

• HITACHI is continually striving to improve its products. We must, therefore, reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.
• ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

TABLE OF CONTENTS:

Kobelco COMPACT LOADER WITH ACCESSORIES SL65B Hydraulic Excavator WORKSHOP MANUAL – PDF DOWNLOAD

COMPACT LOADER WITH ACCESSORIES SL65B………………………………………………….. 1
INDICE………………………………………………………………………….. 4
SECTION 00 – GENERAL INFORMATION……………………………………………….. 23
GENERAL INFORMATION ………………………………………………………. 24
INTRODUCTION………………………………………………………….. 24
ABOUT IMPROVEMENTS…………………………………………………….. 24
COMPANY POLICY………………………………………………………… 25
PARTS AND ACCESSORIES………………………………………………….. 25
MODEL CODES…………………………………………………………… 25
PRECAUTIONARY STATEMENTS……………………………………………….. 26
SAFETY PRECAUTION INFORMATION…………………………………………… 27
GENERAL SAFETY INFORMATION……………………………………………… 29
MACHINE MODEL AND SERIAL NUMBER LOCATION…………………………………. 31
ENGINE MODEL AND SERIAL NUMBER LOCATION………………………………….. 31
HARDWARE TORQUE SPECIFICATIONS………………………………………….. 32
INSTALLATION OF ADJUSTABLE FIT-TINGS IN STRAIGHT THREAD O RING BOSSES……….. 34
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS……………………… 34
PIPE THREAD FITTING TORQUE……………………………………………… 35
LUBRICANTS AND COOLANTS………………………………………………… 35
SEALANTS……………………………………………………………… 35
PROPERLY SUPPORT A RAISED MACHINE……………………………………….. 36
PROPERLY SUPPORT BOOM ON BOOM LOCK PINS………………………………….. 36
RAISING BOOM WITHOUT HYDRAULIC OIL FLOW………………………………….. 36
RAISING BOOM WITHOUT BATTERY VOLTAGE (12 VOLTS)…………………………… 37
REATTACHING CYLINDERS AFTER REPAIR WITH BOOM RESTING ON BOOM LOCK PINS………. 39
MAJOR UNIT OVERHAUL……………………………………………………. 40
CAB AND BOOM TILT PROCEDURE…………………………………………….. 41
CRANING THE SKID STEER…………………………………………………. 47
SPECIAL TOOLS…………………………………………………………. 50
SPECIFICATIONS MODEL SL65B…………………………………………….. 51
DIMENSIONS – SL65B…………………………………………………….. 54
SECTION 10 – ENGINE…………………………………………………………… 57
PAG 2 Indice……………………………………………………………… 58
Chapter 1 – SL65B – 332T/JF………………………………………………… 59
INTRODUCTION………………………………………………………….. 59
SAFETY PRECAUTIONS…………………………………………………. 59
SL65B ENGINE SERVICE……………………………………………….. 60
GENERAL ENGINE INFORMATION………………………………………….. 60
GENERAL ENGINE SPECIFICATIONS……………………………………….. 64
TROUBLESHOOTING……………………………………………………. 66
SPECIFICATIONS SERVICES STANDARDS……………………………………. 75
HARDWARE TORQUE CHART………………………………………………. 82
TORQUE SPECIFICATIONS………………………………………………. 83
TURBOCHARGER TORQUE SPECIFICATIONS…………………………………… 84
ENGINE ELECTRICAL COMPONENTS – SL65B…………………………………. 85
ENGINE REMOVAL BY TILTING THE CAB AND BOOM FORWARD………………………… 86
MOUNTING THE ENGINE FOR MAINTEN-ANCE…………………………………….. 91
ENGINE DISASSEMBLY SEQUENCE…………………………………………….. 91
ENGINE COMPONENT MAINTENANCE………………………………………… 92
CYLINDER BLOCK, PISTONS, RINGS, RODS AND BEARINGS………………………101
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL……………………………….109
CAMSHAFT AND TIMING GEAR TRAIN……………………………………….115
TIMING GEAR………………………………………………………..118
ENGINE TIMING………………………………………………………122
COOLING SYSTEM…………………………………………………………126
THERMOSTAT REMOVAL……………………………………………………..127
WATER PUMP REMOVAL……………………………………………………..128
LUBRICATION SYSTEM……………………………………………………..133
OIL PAN REMOVAL………………………………………………………..133
OIL PUMP REMOVAL……………………………………………………….134
OIL LEVEL DIPSTICK……………………………………………………..137
FUEL SYSTEM………………………………………………………..138
ELECTRIC LIFT PUMP……………………………………………………..138
INJECTORS……………………………………………………………..146
FUEL INJECTOR OVERHAUL………………………………………………….148
ELECTRIC LIFT PUMP……………………………………………………..151
FUEL TANK……………………………………………………………..153
AIR INTAKE AND EXHAUST SYSTEM………………………………………..156
EXHAUST MUFFLER…………………………………………………….158
TURBOCHARGER……………………………………………………….159
STARTING A TURBOCHARGED ENGINE AFTER INSTALLATION OF A TURBOCHARGER………168
ENGINE INSTALLATION…………………………………………………169
OPERATING THE ENGINE AFTER OVERHAUL…………………………………..172
ELECTRICAL COMPONENT MAINTENANCE……………………………………..173
ADJUST BELT TENSION…………………………………………………174
SPECIAL TOOLS………………………………………………………175
SECTION 27 – REAR DRIVE AXLE (GEARBOXES)…………………………………………177
Chapter 1 – Gearboxes………………………………………………………178
GENERAL INFORMATION…………………………………………………….178
SPECIFICATIONS……………………………………………………..180
TROUBLESHOOTING…………………………………………………….181
TESTING……………………………………………………………183
GEARBOXES……………………………………………………………..184
FINAL DRIVE AND GEARBOX FILL/CHECK PLUG (2)……………………………184
GEARBOX REMOVAL………………………………………………………..185
GEARBOX DISASSEMBLY…………………………………………………….186
GEARBOX PARTS INSPECTION…………………………………………….190
GEARBOX REASSEMBLY………………………………………………….191
GEARBOX REINSTALLATION………………………………………………….194
ENGINE-TO-TRANSMISSION GEARBOX……………………………………….199
ENGINE-TO-TRANSMISSION GEARBOX REMOVAL – DISASSEMBLY……………………199
ENGINE-TO-TRANSMISSION GEARBOX PARTS INSPECTION………………………..204
ENGINE-TO-TRANSMISSION GEARBOX REASSEMBLY – INSTALLATION………………..205
START-UP PROCEDURE………………………………………………….208
SECTION 29 – HYDROSTATIC TRANSMISSION……………………………………………211
PAG. 2 INDICE……………………………………………………………..212
PAG. 3 INDICE……………………………………………………………..213
Chapter 1 – Neutralizer, Pumps, Motors, Two-Speed……………………………..214
GENERAL INFORMATION…………………………………………………….214
OPERATION………………………………………………………….214
SPECIFICATIONS……………………………………………………..216
TROUBLESHOOTING………………………………………………………..218
LOW POWER THROUGH THE ENGINE/TRANSMISSION SYSTEM……………………….220
HYDROSTATIC DRIVE SYSTEM TESTING……………………………………..222
HYDROSTATIC SYSTEM OIL FLOW………………………………………….225
HYDROSTATIC CHARGE SYSTEM PRESSURE TEST……………………………….228
HYDROSTATIC PUMP CASE DRAIN TEST……………………………………..230
HYDROSTATIC PUMP HIGH-PRESSURE TEST…………………………………..232
HYDROSTATIC MOTOR CASE DRAIN TEST…………………………………….234
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………236
HYDROSTATIC AND CHARGE PUMPS…………………………………………238
HYDROSTATIC PUMPS…………………………………………………..238
HYDROSTATIC PUMP REMOVAL………………………………………………..238
HYDRAULIC AND CHARGE DISASSEMBLY…………………………………………244
HYDROSTATIC CHARGE PUMP……………………………………………..245
HYDROSTATIC CHARGE PUMP DISASSEMBLY…………………………………..245
HYDROSTATIC CHARGE PUMP PARTS INSPECTION………………………………246
HYDROSTATIC CHARGE PUMP REASSEMBLY……………………………………247
HYDROSTATIC PUMP……………………………………………………248
HYDROSTATIC PUMP DISASSEMBLY…………………………………………248
HYDROSTATIC PUMP PARTS INSPECTION…………………………………….253
HYDROSTATIC PUMP REASSEMBLY………………………………………….259
HYDROSTATIC PUMP REINSTALLATION………………………………………267
MOTORS…………………………………………………………….270
HYDROSTATIC MOTOR – SINGLE SPEED……………………………………..270
HYDROSTATIC MOTOR – SINGLE SPEED REMOVAL………………………………….270
HYDROSTATIC MOTOR – SINGLE SPEED DISASSEMBLY………………………………274
HYDROSTATIC MOTOR – SINGLE SPEED PARTS INSPECTION………………………277
HYDROSTATIC MOTOR – SINGLE SPEED REASSEMBLY……………………………281
HYDROSTATIC MOTOR – SINGLE SPEED REINSTALLATION………………………..285
HYDROSTATIC MOTOR – TWO-SPEED………………………………………..287
HYDROSTATIC MOTOR – TWO-SPEED REMOVAL…………………………………….287
HYDROSTATIC MOTOR – TWO-SPEED DISASSEMBLY……………………………..292
HYDROSTATIC MOTOR – TWO-SPEED PARTS INSPECTION…………………………296
HYDROSTATIC MOTOR – TWO-SPEED REASSEMBLY………………………………300
HYDROSTATIC MOTOR – TWO-SPEED REINSTALLATION…………………………..306
TWO-SPEED HIGH/LOW RANGE COMPONENTS………………………………………309
TWO-SPEED HIGH/LOW CONTROL VALVE…………………………………………311
TWO-SPEED HIGH/LOW CONTROL VALVE REMOVAL………………………………312
TWO-SPEED HIGH/LOW CONTROL VALVE DISASSEMBLY………………………………313
TWO-SPEED HIGH/LOW CONTROL VALVE INSPECTION……………………………313
TWO-SPEED HIGH/LOW CONTROL VALVE REASSEMBLY……………………………314
CONTROL VALVE REINSTALLATION…………………………………………….315
TWO-SPEED HIGH/LOW SLAVE CYLINDER………………………………………..316
TWO-SPEED HIGH/LOW SLAVE CYLINDER REMOVAL…………………………….317
TWO-SPEED HIGH/LOW SLAVE CYLINDER DISASSEMBLY………………………….317
TWO-SPEED HIGH/LOW SLAVE CYLINDER INSPECTION…………………………..318
TWO-SPEED HIGH/LOW SLAVE CYLINDER REASSEMBLY…………………………..318
TWO-SPEED HIGH/LOW SLAVE CYLINDER REINSTALLATION……………………….318
TWO-SPEED HIGH/LOW MOTOR CONTROL LINKAGE………………………………….319
TWO-SPEED HIGH/LOW MOTOR CONTROL LINKAGE REMOVAL……………………….320
TWO-SPEED HIGH/LOW MOTOR CONTROL LINKAGE INSPECTION…………………….321
TWO-SPEED HIGH/LOW MOTOR CONTROL LINKAGE REINSTALLATION…………………322
TWO-SPEED CONTROL SWITCH…………………………………………….323
HYDRAULIC SYSTEM CLEANING PROCEDURE…………………………………..324
START-UP PROCEDURE AFTER REBUILD (AFTER PUMP OR MOTOR REPLACEMENT)……….327
STEERING SYSTEM………………………………………………………..330
HYDROSTATIC SYSTEM CONTROLS………………………………………….330
NEUTRALIZER ASSEMBLY………………………………………………..332
NEUTRALIZER ASSEMBLY REMOVAL…………………………………………….332
NEUTRALIZER ASSEMBLY DISASSEMBLY……………………………………..332
NEUTRALIZER ASSEMBLY INSPECTION………………………………………333
NEUTRALIZER ASSEMBLY REASSEMBLY………………………………………335
CONTROL LINKAGE………………………………………………………..337
CONTROL LINKAGE REMOVAL……………………………………………..337
CONTROL LINKAGE DISASSEMBLY………………………………………….337
CONTROL LINKAGE INSPECTION…………………………………………..337
CONTROL LINKAGE REASSEMBLY…………………………………………..338
LEFT CONTROL HANDLE WITH NO BOOM CONTROL………………………………339
LEFT CONTROL HANDLE WITH NO BOOM CONTROL REMOVAL…………………………..339
LEFT CONTROL HANDLE WITH NO BOOM CONTROL DISASSEMBLY……………………339
LEFT CONTROL HANDLE WITH NO BOOM CONTROL INSPECTION…………………….340
LEFT CONTROL HANDLE WITH NO BOOM CONTROL REASSEMBLY…………………….340
LEFT CONTROL HANDLE WITH NO BOOM CONTROL REINSTALLATION…………………340
LEFT CONTROL HANDLE WITH BOOM CONTROL…………………………………342
LEFT CONTROL HANDLE WITH BOOM CONTROL REMOVAL……………………………..342
LEFT CONTROL HANDLE WITH BOOM CONTROL DISASSEMBLY………………………343
LEFT CONTROL HANDLE WITH BOOM CONTROL INSPECTION……………………….344
LEFT CONTROL HANDLE WITH BOOM CONTROL REASSEMBLY……………………….345
LEFT CONTROL HANDLE WITH BOOM CONTROL REINSTALLATION……………………346
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL…………………..348
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL REMOVAL……………….348
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL DISASSEMBLY………..349
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL INSPECTION…………351
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL REASSEMBLY…………352
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL REINSTALLATION……..355
CONTROL LINKAGE AND NEUTRALIZER………………………………………357
CONTROL LINKAGE AND NEUTRALIZER ……………………………………..357
DRIVE CONTROL ADJUSTMENT PRO-CEDURE………………………………………358
SL65B LINKS AND ARMS………………………………………………..359
SL65B NEUTRALIZER ADJUSTMENT…………………………………………….360
CONTROL LEVER PARALLEL ADJUSTMENT…………………………………….361
SL65B LINKAGE AND CONTROL LEVER EQUAL MOVEMENT…………………………361
LEFT CONTROL LINKAGE ADJUSTMENT………………………………………362
SL65B STRAIGHT TRAVEL AND FORWARD/REVERSE STOP ADJUSTMENT……………….362
SL65B HIGH/LOW RANGE ADJUSTMENT (OPTIONAL)…………………………….365
SECTION 33 – BRAKES AND CONTROLS………………………………………………..367
Chapter 1 – Parking Brake…………………………………………………..368
GENERAL INFORMATION…………………………………………………….368
SPECIFICATIONS……………………………………………………..369
TROUBLESHOOTING…………………………………………………….370
TESTING……………………………………………………………372
PARKING BRAKE………………………………………………………….373
PARKING BRAKE REMOVAL AND INSPECTION………………………………….374
PARKING BRAKE ADJUSTMENT…………………………………………….379
SECTION 35 – HYDRAULIC SYSTEM…………………………………………………..381
SECTION 35 – HYDRAULIC SYSTEM…………………………………………………..382
Chapter 1 – Valves, Gear Pump, Cylinders, and Pedal Controls……………………383
GENERAL INFORMATION…………………………………………………….383
HYDRAULIC SYSTEM COMPATIBILITY……………………………………….384
BOOM CYLINDER PIVOT PINS…………………………………………….386
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE………………….386
CONTROL VALVE POWER BEYOND…………………………………………..387
SPECIFICATIONS……………………………………………………..388
TROUBLESHOOTING…………………………………………………….391
AUXILIARY BOOM HYDRAULICS TROUBLESHOOTING……………………………..395
HYDRAULIC SYSTEM TESTING…………………………………………….397
HYDRAULIC SYSTEM OIL FLOW……………………………………………403
CONTROL VALVE – BUCKET SPOOL SHIFTED………………………………….404
CONTROL VALVE – BOOM SPOOL SHIFTED……………………………………405
CONTROL VALVE – AUXILIARY SPOOL SHIFTED……………………………….406
HYDRAULIC SYSTEM OIL FLOW……………………………………………407
MAIN SYSTEM PRESSURE TESTS………………………………………………409
CHECKING MAIN SYSTEM PRESSURE AT BOOM CYLINDERS………………………..412
CHECKING MAIN SYSTEM PRESSURE AT BUCKET CYLINDERS………………………413
CHECKING MAIN SYSTEM PRESSURE AT AUXILIARY BOOM HYDRAULIC QUICK COUPLERS….414
BOOM CIRCUIT RELIEF VALVE TEST……………………………………….415
GEAR PUMP FLOW EFFICIENCY TEST……………………………………….417
BOOM AND BUCKET SPOOL LOCK SOLE-NOID TEST……………………………..420
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………422
CONTROL VALVE Specifications…………………………………………424
CONTROL VALVE REMOVAL…………………………………………………..425
CONTROL VALVE DISASSEMBLY AND INSPECTION………………………………….427
CONTROL VALVE PARTS INSPECTION……………………………………….431
CONTROL VALVE REASSEMBLY…………………………………………….432
CONTROL VALVE REINSTALLATION…………………………………………436
HYDRAULIC PUMP SPECIFICATIONS………………………………………..437
HYDRAULIC PUMP REMOVAL………………………………………………….438
HYDRAULIC PUMP DISASSEMBLY………………………………………………440
HYDRAULIC PUMP PARTS INSPECTION………………………………………441
HYDRAULIC PUMP REASSEMBLY……………………………………………443
HYDRAULIC PUMP INSTALLATION………………………………………….446
CYLINDERS, BOOM AND BUCKET…………………………………………..449
BOOM CYLINDER REMOVAL…………………………………………………..450
BOOM CYLINDER DISASSEMBLY……………………………………………451
BOOM CYLINDER PARTS INSPECTION……………………………………….453
BOOM CYLINDER REASSEMBLY…………………………………………….454
BOOM CYLINDER REINSTALLATION…………………………………………456
BUCKET CYLINDER REMOVAL…………………………………………………457
BUCKET CYLINDER DISASSEMBLY……………………………………………..457
BUCKET CYLINDER PARTS INSPECTION……………………………………..458
BUCKET CYLINDER REASSEMBLY…………………………………………..460
BUCKET CYLINDER REINSTALLATION……………………………………….462
PEDAL CONTROLS……………………………………………………..463
PEDAL REMOVAL (With Boom and Bucket Pedal Controls)………………………..463
PEDAL INSPECTION (With Boom and Bucket Pedal Controls)………………….463
PEDAL REINSTALLATION (With Boom and Bucket Pedal Controls)………………465
PEDAL REMOVAL (With Boom and Bucket Hand Controls)…………………………468
PEDAL INSPECTION (With Boom and Bucket Hand Controls)…………………..469
PEDAL REINSTALLATION (With Boom and Bucket Hand Controls)……………….470
HYDRAULIC COOLING, FILTER, RESERVOIR SYSTEM……………………………….473
FILTER SYSTEM………………………………………………………474
FILTER REMOVAL……………………………………………………..474
BASE REMOVAL……………………………………………………….474
REASSEMBLY……………………………………………………..475
OIL COOLER……………………………………………………..476
OIL COOLER REMOVAL………………………………………………….476
OIL COOLER REASSEMBLY……………………………………………476
OIL RESERVOIR………………………………………………………477
OIL RESERVOIR REMOVAL……………………………………………….478
OIL RESERVOIR INSPECTION…………………………………………479
OIL RESERVOIR REINSTALLATION……………………………………..480
ADAPTING ATTACHMENTS…………………………………………….481
SECTION 37 – TOWING HOOKS AND BALLASTING…………………………………………483
Chapter 1 – Rear Counter Weights…………………………………………….484
REAR COUNTERWEIGHTS…………………………………………………….484
REAR COUNTERWEIGHT SUPPORT REMOVAL……………………………………….484
SECTION 39 – FRAMES……………………………………………………………485
Chapter 1 – Lower Main, ROPS………………………………………………..486
GENERAL INFORMATION…………………………………………………….486
ROPS………………………………………………………………….486
ROPS FRAME…………………………………………………………….486
ROPS REMOVAL…………………………………………………………..486
REINSTALLATION…………………………………………………………493
SECTION 44 – AXLES AND WHEELS…………………………………………………..497
Chapter 1 – Axles………………………………………………………….498
GENERAL INFORMATION…………………………………………………….498
SPECIFICATIONS……………………………………………………..500
TROUBLESHOOTING…………………………………………………….501
TESTING……………………………………………………………503
AXLES…………………………………………………………………504
AXLE HOUSING ASSEMBLY REMOVAL……………………………………………504
AXLE DISASSEMBLY……………………………………………………….505
AXLE PARTS INSPECTION……………………………………………….507
AXLE REASSEMBLY…………………………………………………….508
AXLE HOUSING REINSTALLATION………………………………………….510
FINAL DRIVE………………………………………………………..512
DRIVE CHAIN AND SPROCKET REMOVAL…………………………………………512
FINAL DRIVE PARTS INSPECTION…………………………………………514
FINAL DRIVE REASSEMBLY………………………………………………515
TYRES/WHEELS…………………………………………………………..518
TYRE AND TRACK INSTALLATION………………………………………….519
SECTION 50 – CAB CLIMATE CONTROL………………………………………………..521
Chapter 1 – Heater/Defroster………………………………………………..522
HEATER/DEFROSTER (CAB)………………………………………………….522
SECTION 55 – ELECTRICAL SYSTEM…………………………………………………. 16
SECTION 55 – ELECTRICAL SYSTEM………………………………………………….529
SECTION 55 – ELECTRICAL SYSTEM………………………………………………….530
SECTION 55 – ELECTRICAL SYSTEM………………………………………………….531
SECTION 55 – ELECTRICAL SYSTEM………………………………………………….532
Chapter 1 – Advanced Warning System, Circuits, Alternator, and Starter…………..534
GENERAL ELECTRICAL INFORMATION…………………………………………..534
DEFINITION OF TERMS…………………………………………………535
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………….537
SPECIFICATIONS……………………………………………………..542
ELECTRICAL DIAGRAM………………………………………………….545
ADVANCED WARNING SYSTEM…………………………………………………549
ELECTRONIC INSTRUMENT CLUSTER (EIC)…………………………………..549
EIC (ELECTRONIC INSTRUMENT CLUSTER) FRONT PANEL………………………..550
EIC FUNCTIONAL GROUPS……………………………………………….551
ENGINE PREHEAT……………………………………………………..556
AUTOMATIC SHUTDOWN………………………………………………….556
OPERATING MODE……………………………………………………..557
BROKEN ALTERNATOR/WATER PUMP BELT WARNING……………………………..559
FUEL LEVEL…………………………………………………………560
EIC INTERLOCKS……………………………………………………..560
EIC LOCK MODE………………………………………………………561
EIC ENGINE PREHEAT………………………………………………….562
TROUBLESHOOTING…………………………………………………….563
ADVANCED WARNING SYSTEM (AWS)………………………………………..566
EIC BOARD SELF TEST…………………………………………………567
DIAGNOSTIC AND SETUP MODES…………………………………………..568
DIAGNOSTIC MODE EIC CIRCUIT TESTS…………………………………….570
EIC SETUP MODE……………………………………………………..574
ELECTRONIC INSTRUMENT CLUSTER (EIC) AND STARTER CIRCUITS………………..582
BLOWN FUSE SYMPTOMS AND TESTING………………………………………582
TESTING OTHER EIC FUNCTIONS………………………………………….584
EIC BOARD READING ACCURACY…………………………………………..587
EIC BOARD CLAIMS WARRANTY……………………………………………590
ELECTRICAL CIRCUITS…………………………………………………591
SEAT SWITCH CIRCUIT TO EIC BOARD……………………………………..592
SEAT BELT SWITCH CIRCUIT TO EIC BOARD…………………………………593
IGNITION SWITCH CIRCUIT TO EIC BOARD………………………………….595
CRANKING CIRCUIT (STARTER MOTOR)……………………………………..596
“SERVICE/RUN” SWITCH IN THE “RUN” POSITION…………………………….597
CRANKING CIRCUIT GROUND……………………………………………..598
SERVICE/RUN SWITCH IN THE “SERVICE” POSITION…………………………..599
CRANKING CIRCUIT GROUND……………………………………………..600
START RELAY OPERATION……………………………………………….600
START RELAY CIRCUIT…………………………………………………601
START RELAY GROUND CIRCUIT…………………………………………..602
START INTERLOCK RELAY OPERATION………………………………………602
START INTERLOCK CIRCUIT……………………………………………..603
START INTERLOCK GROUND CIRCUIT……………………………………….604
START CIRCUIT………………………………………………………604
REMOVAL, INSTALLATION AND WIRING OF ELECTRICAL COMPONENTS…………………..605
BATTERY……………………………………………………………606
BATTERY REMOVAL………………………………………………………..606
INSTALLATION……………………………………………………….606
EIC (ELECTRONIC INSTRUMENT CLUSTER) BOARD REMOVAL………………………….607
EIC (ELECTRONIC INSTRUMENT CLUSTER) WIRING…………………………….608
EIC (ELECTRONIC INSTRUMENT CLUSTER) BOARD INSTALLATION………………….609
EIC (ELECTRONIC INSTRUMENT CLUSTER) BOARD INSTALLATION………………….609
IGNITION (KEY) SWITCH WIRING…………………………………………609
IGNITION (KEY) SWITCH REMOVAL……………………………………………610
IGNITION (KEY) SWITCH INSTALLATION……………………………………610
CAB FUSE PANEL WIRING……………………………………………….611
CAB FUSE BLOCK AND PANEL REMOVAL……………………………………..612
CAB FUSE BLOCK AND PANEL INSTALLATION…………………………………612
SERVICE/RUN SWITCH WIRING……………………………………………613
SERVICE/RUN SWITCH – SERVICE POSITION…………………………………613
SERVICE/RUN SWITCH – RUN POSITION…………………………………….613
SERVICE/RUN SWITCH REMOVAL………………………………………………614
SERVICE/RUN SWITCH INSTALLATION………………………………………614
SEAT AND SEAT BELT SWITCH WIRING……………………………………..614
SEAT SWITCH REMOVAL…………………………………………………….615
SEAT SWITCH INSTALLATION…………………………………………….615
SEAT BELT BUCKLE AND SWITCH ASSEMBLY REMOVAL…………………………..616
SEAT BELT BUCKLE INSTALLATION………………………………………..616
ROAD LIGHT AND WORK LIGHT SWITCH WIRING……………………………….616
ROAD LIGHT AND WORK LIGHT SWITCH REMOVAL………………………………….617
ROAD LIGHT AND WORK LIGHT SWITCH INSTALLATION………………………….617
ROAD LIGHT AND WORK LIGHT SWITCH REMOVAL………………………………617
ROAD LIGHT AND WORK LIGHT SWITCH INSTALLATION………………………….617
ENGINE FUSE AND RELAY PANEL………………………………………….618
ACCESSORY RELAY WIRING………………………………………………619
ACCESSORY RELAY WIRING REMOVAL……………………………………….619
ACCESSORY RELAY WIRING INSTALLATION…………………………………..619
PREHEAT CIRCUIT BREAKER WIRING……………………………………….619
PREHEAT CIRCUIT BREAKER REMOVAL………………………………………….619
PREHEAT CIRCUIT BREAKER INSTALLATION………………………………….619
START INTERLOCK RELAY WIRING…………………………………………620
START INTERLOCK RELAY REMOVAL……………………………………………621
START INTERLOCK RELAY INSTALLATION……………………………………621
ENGINE FUSE PANEL WIRING…………………………………………….621
ENGINE FUSE BLOCK REMOVAL……………………………………………622
ENGINE FUSE BLOCK INSTALLATION……………………………………….622
ALTERNATOR EXCITE RESISTOR WIRING…………………………………….623
ALTERNATOR EXCITE RESISTOR REMOVAL……………………………………….623
ALTERNATOR EXCITE RESISTOR INSTALLATION……………………………….623
START RELAY WIRING………………………………………………….624
START RELAY REMOVAL…………………………………………………….624
START RELAY INSTALLATION…………………………………………….625
PREHEAT RELAY WIRING………………………………………………..625
PREHEAT RELAY REMOVAL…………………………………………………..626
PREHEAT RELAY INSTALLATION…………………………………………..626
PREHEAT MANIFOLD HEATER REMOVAL………………………………………626
PREHEAT MANIFOLD HEATER INSTALLATION………………………………….626
FUEL SYSTEM COMPONENTS………………………………………………627
FUEL SHUTOFF SOLENOID…………………………………………………..629
FUEL SHUTOFF SOLENOID TESTING………………………………………..629
REPLACEMENT OF FUEL SHUTOFF SOLENOID……………………………………..630
ELECTRIC LIFT PUMP………………………………………………….630
ELECTRIC LIFT PUMP REMOVAL…………………………………………..631
COLD ADVANCE SWITCH REMOVAL………………………………………….631
COLD ADVANCE SWITCH INSTALLATION……………………………………..631
AIR FILTER RESTRICTION INDICATOR SWITCH REMOVAL……………………………631
AIR FILTER RESTRICTION INDICATOR SWITCH INSTALLATION……………………631
ENGINE COOLANT TEMPERATURE SENDER REMOVAL…………………………………632
ENGINE COOLANT TEMPERATURE SENDER INSTALLATION…………………………632
ENGINE OIL PRESSURE SWITCH REMOVAL……………………………………….633
ENGINE OIL PRESSURE SWITCH INSTALLATION……………………………….633
HYDROSTATIC CHARGE PRESSURE SWITCH REMOVAL………………………………..633
HYDROSTATIC CHARGE PRESSURE SWITCH INSTALLATION………………………..633
HYDRAULIC OIL FILTER RESTRICTION SWITCH REMOVAL……………………………634
HYDRAULIC OIL FILTER RESTRICTION SWITCH INSTALLATION……………………634
HYDRAULIC OIL TEMPERATURE SENDER REMOVAL………………………………….634
HYDRAULIC OIL TEMPERATURE SENDER INSTALLATION………………………….636
BOOM/BUCKET CONTROL VALVE SPOOL LOCK SOLENOIDS…………………………636
REMOVAL……………………………………………………………….636
INSTALLATION……………………………………………………….637
WIRE HARNESS……………………………………………………….638
MAIN WIRE HARNESS REMOVAL……………………………………………….638
MAIN WIRE HARNESS INSTALLATION……………………………………….643
ROAD/WORK LIGHTS……………………………………………………….647
ALTERNATOR(45 AMP VERSION)………………………………………………651
CHARGING SYSTEM…………………………………………………….651
ALTERNATOR…………………………………………………………653
ALTERNATOR SYSTEM TESTING AND TROUBLESHOOTING………………………….653
ALTERNATOR COMPONENT TESTS…………………………………………..657
ALTERNATOR OVERHAUL AND COMPONENT TESTING……………………………..659
ALTERNATOR REMOVAL……………………………………………………..659
DISASSEMBLY……………………………………………………………660
ALTERNATOR COMPONENT TEST……………………………………………….661
INSPECTION AND REPAIR……………………………………………….663
REASSEMBLY…………………………………………………………664
REINSTALLATION……………………………………………………..664
STARTER……………………………………………………………….665
STARTER MOTOR TROUBLESHOOTING………………………………………..667
REMOVAL……………………………………………………………….668
STARTER MAINTENANCE…………………………………………………669
SYSTEM TESTING……………………………………………………..669
STARTER MOTOR CURRENT DRAW…………………………………………..670
DISASSEMBLY………………………………………………………..672
REASSEMBLY…………………………………………………………673
INSPECTION AND REPAIR……………………………………………….673
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)………………………………. 20
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)……………………………675
GENERAL INFORMATION…………………………………………………….676
BUCKETS……………………………………………………………676
BOOM LOCK PINS AND LINKAGE………………………………………………677
BOOM………………………………………………………………677
ATTACHMENT MOUNTING PLATE……………………………………………….678
BOOM AND CYLINDER PIVOT PINS…………………………………………678
BOOM AND CYLINDER PIVOT PIN LOCA-TION AND MACHINE USAGE…………………678
BOOM/CYLINDER PIVOT PINS SIZE………………………………………..679
PALLET FORK……………………………………………………………680
UTILITY FORK…………………………………………………………..681
BUCKETS CUTTING EDGE (REPLACEMENT)……………………………………….682
BUCKET LATCH PLATE INSTALLATION PROCEDURE…………………………………683
DIRT TOOTH KIT INSTALLATION……………………………………………..686
BUCKET TOOTH SPACING………………………………………………..687
BOOM LOCK PIN LINKAGE……………………………………………….689
REMOVAL……………………………………………………………….689
REINSTALLATION……………………………………………………..691
BOOM, UPPER AND LOWER LINK…………………………………………..692
REMOVAL……………………………………………………………692
FRONT BOOM MOUNTING PLATE PIVOT HUB REPLACEMENT……………………………698
BOOM, UPPER AND LOWER LINK REINSTALLATION……………………………..699
ATTACHMENT MOUNTING PLATE……………………………………………704
REMOVAL……………………………………………………………….704
REPAIR/REBUILD MOUNTING PLATE………………………………………..704
LATCH LEVER AND PIN REMOVAL/REPAIR……………………………………….704
PARTS INSPECTION……………………………………………………707
CHECKING PROCEDURE FOR BUCKETS AND ATTACHMENTS…………………………712
CHECKING PROCEDURE………………………………………………….714
CHECKING THE LOADER FACEPLATE………………………………………..715
SECTION 88 – ACCESSORIES………………………………………………………. 21
SECTION 88 – ACCESSORIES……………………………………………………717
GENERAL INFORMATION…………………………………………………….718
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………….718
HYDRAULIC SYSTEM COMPATIBILITY……………………………………….722
ARM PADS FOR CAB SIDE PANELS…………………………………………….724
ARMRESTS FOR DELUXE SEAT………………………………………………..724
FOREARM RESTS………………………………………………………….725
BACK-UP ALARM………………………………………………………….726
BLOCK HEATER (ENGINE)…………………………………………………..727
ELECTRIC POWER SUPPLY (12 VOLT, 15 AMP)…………………………………..729
EXHAUST (ENGINE)……………………………………………………….730
ASPIRATOR PRECLEANER MUFFLER…………………………………………….730
HIGH-FLOW HYDRAULICS……………………………………………………731
HIGH-FLOW HYDRAULICS TROUBLESHOOTING………………………………….733
HIGH-FLOW HYDRAULICS COMPONENT REPLACEMENT…………………………….735
HIGH-FLOW HYDRAULICS OPERATION……………………………………….738
HORN………………………………………………………………….742
SHOULDER BELT (SEAT)……………………………………………………743
SLOW-MOVING VEHICLE (SMV) SIGN KIT……………………………………….744
TYRES/WHEELS…………………………………………………………..744
TYRE AND TRACK INSTALLATION………………………………………….745
BUCKET AND Tyre COMBINATION CHART…………………………………….747
WARNING LIGHT (ROTARY BEACON)……………………………………………748
WARNING LIGHTS (FOUR-WAY FLASHERS/TURN SIGNAL/HORN)………………………..750
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS…………………………………. 22
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS………………………………755
GENERAL INFORMATION…………………………………………………….756
SEAT AND SEAT PAN SUPPORT……………………………………………756
CAB INNER SHELL………………………………………………………..757
SEAT REMOVAL…………………………………………………………..757
SEAT PAN SUPPORT REMOVAL………………………………………………..757
SEAT, SWITCH AND PAN REINSTALLATION…………………………………..759
CAB INNER SHELL…………………………………………………….761
REMOVAL……………………………………………………………….761
REINSTALLATION……………………………………………………..768
SAFETY DECALS………………………………………………………….775

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