CUSTOM SERVICE INFORMATION for the 980H UNDERGROUND MINE AR {1050, 1051, 4250, 4267, 4300, 4307, 4330, 5050, 5109, 5112, 5134, 7000} Caterpillar

Wheel Loader:

980H (S/N: MHG1-UP; JMS1-UP)

Introduction

This Special Instruction contains the information for the Disassembly and Assembly of the parking brake, the steering pilot valve, the pilot operated hydraulic control valve and air cleaner. This special instruction contains the testing procedure for the parking brake, the steering neutralizer valve, and the hydraulic lift kickout and the hydraulic tilt kickout. These instructions contain the adjustment procedure for the parking brake, the steering neutralizer valve, and the hydraulic lift kickout and the hydraulic tilt kickout.

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Pilot Valve (Steering) - Remove

Removal Procedure

1. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. Plugging helps to prevent fluid loss and helps to keep contaminants from entering the system.

Note: Cleanliness is an important factor. Before the removal procedure, thoroughly clean the exterior of the component. Cleaning will help to prevent dirt from entering the internal mechanism.

Show/hide table



Illustration 1	g01945204

1. Disconnect four hose assemblies (1) from the pilot valve (2) .

Show/hide table



Illustration 2	g01945207

2. Remove bolt (4) and the nut. Remove two bolts (3) and the washer. Remove the steering pilot valve from steering shaft (5) .

Pilot Valve (Steering) - Disassemble

Disassembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0520	Driver Group	1
B	1P-1861	Retaining Ring Pliers	1
C	1P-1863	Retaining Ring Pliers	1

1. Remove the steering pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (Steering) - Remove".

Note: Cleanliness is an important factor. Before the disassembly procedure, thoroughly clean the exterior of the component. Cleaning will help to prevent dirt from entering the internal mechanism.

Show/hide table



Illustration 3	g01945212

1. Remove mounting bracket (1) .

2. Remove check valves (2) .

Show/hide table



Illustration 4	g01945213

Show/hide table



Illustration 5	g01945215

3. Remove bolts (3) and actuator assembly (4) .

Show/hide table



Illustration 6	g01945216

4. Loosen nut (5). Remove retainer assembly (6) .

Show/hide table



Illustration 7	g01945219

5. Remove O-ring seal (7) .

Show/hide table



Illustration 8	g01945221

6. Mark the position of the key on shaft (8) for assembly purposes. Remove pin (9) that holds actuator (10) to shaft (8) .

Show/hide table



Illustration 9	g01945222

7. Remove lip seal (11) .

Show/hide table



Illustration 10	g01945223

8. Use Tooling (A) in order to remove retainer ring (12) .

Show/hide table



Illustration 11	g01945266

Show/hide table



Illustration 12	g01945267

9. Remove shaft assembly (8) and actuator (10) .

Show/hide table



Illustration 13	g01945268

10. Use Tooling (B) in order to remove retaining ring (14) and bearing (13) from the shaft.

Show/hide table



Illustration 14	g01945272

11. Remove bearing (15) from the cover.

Show/hide table



Illustration 15	g01945275

Show/hide table

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

12. Measure the distance from nut face (17) to the end of sleeve (18). Record this measurement for assembly purposes.

13. Loosen nut (17). Remove sleeve (18), nut (17) and plunger (19). Remove O-ring seal (16) .

Show/hide table



Illustration 16	g01945276

Show/hide table



Illustration 17	g01945277

14. Measure the distance from the nut face to the end of the threads on stem (20). Record this measurement for assembly purposes.

Show/hide table

Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

15. Remove nut (26), nut (25), retainer (24), spring (23), spring (22) and slug (21) from stem (20) .

16. Repeat steps 14 through 15 for the removal of spool assembly (27) .

Pilot Valve (Steering) - Assemble

Assembly Procedure

Table 2

Required Tools
Tool	Part Number	Part Description	Qty
B	1P-1861	Retaining Ring Pliers	1
C	1P-1863	Retaining Ring Pliers	1

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Show/hide table



Illustration 18	g01945286

Show/hide table

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

1. Install spring (22), spring (23), retainer (24), nut (25), nut (26), and slug (21) on stem (20). Tighten nut (26) and nut (25) until the measurement that was recorded during disassembly is obtained.

Show/hide table



Illustration 19	g01945288

Show/hide table



Illustration 20	g01945289

Show/hide table

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

2. Install spool assembly (20) .

3. Install sleeve (18), nut (17) and plunger (19). Adjust the sleeve and the nut until the measurement that was recorded during disassembly is obtained.

4. Repeat steps 1 through 3 for the installation of spool assembly (27) .

5. Install O-ring seal (16) .

Show/hide table



Illustration 21	g01947172

6. Install bearing (15) in the cover.

Show/hide table



Illustration 22	g01947155

7. Use Tooling (B) in order to install bearing (13) and retaining ring (14) on the shaft.

Show/hide table



Illustration 23	g01947160

8. Install shaft assembly (8) and actuator (10) .

Show/hide table



Illustration 24	g01947165

9. Use Tooling (A) in order to install retainer ring (12) .

Show/hide table



Illustration 25	g01945299

10. Align the key on shaft (8) with the alignment mark that was made during the disassembly procedure. Install pin (9) in actuator (10) and shaft (8) .

Show/hide table



Illustration 26	g01945301

11. Install lip seal (11) .

Show/hide table



Illustration 27	g01945303

Show/hide table



Illustration 28	g01945305

12. Install O-ring seal (7), retainer assembly (6), and nut (5). Adjust the retainer and the nut until the measurement that was recorded during disassembly is obtained.

Show/hide table



Illustration 29	g01945308

Show/hide table



Illustration 30	g01945310

13. Install actuator assembly (4) and bolts (3). Tighten the bolts to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

Show/hide table



Illustration 31	g01945313

14. Install check valves (2) .

15. Install the mounting bracket (1) .

16. Install the steering pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (Steering) - Install".

Pilot Valve (Steering) - Install

Installation Procedure

Show/hide table



Illustration 32	g01945333

1. Install the steering pilot valve, two bolts (3) and the washer.

2. Install steering shaft (5), bolt (4) and the nut.

Show/hide table



Illustration 33	g01947215

3. Connect four hose assemblies (1) to the pilot valve (2) .

4. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

Parking Brake - Remove

Removal Procedure

1. Remove the cab. Refer to Disassembly and Assembly, "Cab - Remove".

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Show/hide table



Illustration 34	g01932575

1. Disconnect hose assembly (2) from parking brake (1) .

Show/hide table



Illustration 35	g01932577

2. Remove bolts (3) from plate (4) .

Show/hide table



Illustration 36	g01932578

3. Install bolt (3) in plate (4) in order to release the parking brake.

Show/hide table



Illustration 37	g01932579

4. Disconnect hose assembly (5).

Show/hide table



Illustration 38	g01932582

5. Attach a suitable lifting device to parking brake assembly (1). The weight of parking brake assembly (1) is approximately 64 kg (140 lb). Remove bolts (8) and remove parking brake assembly (1) .

Parking Brake - Disassemble

Disassembly Procedure

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-7405	Eyebolt	1

1. Remove the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Remove".

Show/hide table



Illustration 39	g01932597

1. Remove springs (7) from pressure plate (8) .

2. Remove pressure plate (8). Remove plates (9) and brake disc assemblies (10) .

Show/hide table



Illustration 40	g01932598

3. Remove retainer (11) and hub (12). Remove the O-ring seal.

Show/hide table



Illustration 41	g01932600

4. Remove brake shaft (13) from the bottom side of the bearing cage.

Show/hide table



Illustration 42	g01932602

5. Remove lip seal (14), retaining ring (15), and bearing (16) from the bearing cage.

Parking Brake - Assemble

Assembly Procedure

Table 4

Required Tools
Tool	Part Number	Part Description	Qty
B	1P-0520	Driver Group	1

Show/hide table



Illustration 43	g01932614

Show/hide table



Illustration 44	g01932615

1. Install bearing (16) in the bearing cage. Make sure Bearing (16) contact the counterbore in the bearing cage. Install retaining ring (15) that holds bearing (16) in position.

2. Use Tooling (A) to install lip seal (14) in the bearing cage. Install lip seal (14) until lip seal (14) contacts the counterbore in the bearing cage. The edge of lip seal (14) should be even with the surface of the brake.

Show/hide table



Illustration 45	g01932617

3. Install brake shaft (13) from the bottom of the bearing cage, as shown.

Show/hide table



Illustration 46	g01932619

4. Install hub (12), the O-ring seal, and retainer (11) over the brake shaft.

Show/hide table



Illustration 47	g01932620

5. Install brake disc assemblies (10) and plates (9) in alternating order. Start with a brake disc assembly (10) and end with a brake disc assembly (10) .

6. Install pressure plate (8). Install springs (7) .

Show/hide table



Illustration 48	g01932621

Show/hide table

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

7. Put brake housing assembly (6) in position. Install bolts (5) that hold brake housing assembly (6) in position on the pressure plate.

8. Install the O-ring seal, the backup ring, and the lip seal in the bore of the brake housing assembly. Repeat for the remaining pistons.

9. Install spacers (3) on brake housing assembly (6) .

Show/hide table



Illustration 49	g01932633

Show/hide table

Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

10. Install plate (2) and bolts (1) that hold the brake housing in position. Tighten bolts (1) to a torque of 140 ± 14 N·m (103 ± 10 lb ft).

11. Install the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Install".

Parking Brake - Install

Installation Procedure

Show/hide table



Illustration 50	g01933114

1. Attach a suitable lifting device to parking brake assembly (1). The weight of parking brake assembly (1) is approximately 64 kg (140 lb). Install parking brake assembly (1) and install bolts (8) .

Show/hide table



Illustration 51	g01933115

2. Connect hose assembly (5) .

Show/hide table



Illustration 52	g01933116

3. Remove bolt (3) from plate (4) in order to engage the parking brake.

Show/hide table



Illustration 53	g01933119

4. Install bolts (3) into plate (4) .

Show/hide table



Illustration 54	g01933120

5. Connect hose assembly (2) to parking brake (1) .

Pilot Operated Hydraulic Control - Remove

Removal Procedure

1. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

2. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "System Pressure - Release".

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Put identification on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses, and all tubes. Plugs help to prevent fluid loss and helps to keep contaminants from entering the system.

Show/hide table



Illustration 55	g01933153
Typical Example

1. Remove three screws (1) from control cover (3) .

Show/hide table



Illustration 56	g01933154

2. Remove two screws (4) from control cover (3) .

Show/hide table



Illustration 57	g01991424

3. Remove two screws (4) from control cover (3) .

Show/hide table



Illustration 58	g01933155

4. Remove four screws (5) from control cover (3) .

5. Remove control cover (3) .

Show/hide table



Illustration 59	g01933173

6. Disconnect two electrical connectors (6) .

Show/hide table



Illustration 60	g01933175

7. Disconnect six hose assemblies (7) .

Show/hide table



Illustration 61	g01933178

8. Remove four nuts (8) that fasten hydraulic control valve (9) to support assembly (10) .

Show/hide table



Illustration 62	g01933179

9. Remove hydraulic control valve (9) from the cab.

Pilot Operated Hydraulic Control - Disassemble

Disassembly Procedure

1. Remove the hydraulic control. Refer to Disassembly and Assembly, "Pilot Operated Hydraulic Control - Remove".

Show/hide table



Illustration 63	g01933186

2. Remove grommet (4) and pull wire through plate assembly.

3. Loosen two nuts (3). Remove control rods (1) and (2) .

Show/hide table



Illustration 64	g01933193

4. Remove two boots (5) .

Show/hide table



Illustration 65	g01933195

5. Remove spring clips (7) and pins (8) .

6. Remove pivot plates (6) .

Show/hide table



Illustration 66	g01933196

7. Remove two screws (9), brackets (10), and clamps (11) .

Show/hide table



Illustration 67	g01933197

8. Remove four screws (12) and plate assembly (13) .

Show/hide table



Illustration 68	g01933198

9. Mark the location of six wires in connector (14) .

10. Remove wedge (15) from connector (14) .

11. Carefully remove six wires from connector (14) .

Show/hide table



Illustration 69	g01933199

12. Mark the location of each body assembly.

13. Remove body assemblies (16) and (17) .

Note: Step 14 and step15 are for the disassembly of body assembly (16). Body assembly (17) has two magnetic detent coils. The disassembly procedure is identical.

Show/hide table



Illustration 70	g01933201

14. Remove gaskets (18) from the body assembly.

Show/hide table



Illustration 71	g01933202

15. Remove the following items from valve body (20) : two plunger shafts (25), coil assembly (23), sleeve (24), two plunger covers (22), two springs (21) and two bushings (19) .

Note: Steps 16 through 25 are for the disassembly of the valve body.

Show/hide table



Illustration 72	g01933213

16. Remove three nuts (26). Separate valve groups (27) and (28) .

Note: Valve group (27) is for the tilt circuit. Valve group (28) is for the lift circuit.

Note: Steps 17 through 25 are for the disassembly of valve group (28) for the lift circuit.

Show/hide table



Illustration 73	g01933215

17. Remove two O-ring seals (29) and two fittings (30) .

Show/hide table



Illustration 74	g01933217

Show/hide table



Illustration 75	g01933218

18. Remove two valve assemblies (31). The valve assembly includes the valve body, the spring, and the spool.

Show/hide table



Illustration 76	g01933220

19. Remove the following items from valve body (34) : O-ring seal (32), O-ring seal (33) and backup ring (35) .

Show/hide table



Illustration 77	g01933223

20. Remove pin (38) and seat (36) from spool (37) .

Show/hide table



Illustration 78	g01933225

21. Remove two caps (41) from plunger capsule assemblies (39) and (40) .

Show/hide table



Illustration 79	g01933227

Note: Mark the location of each plunger capsule assembly prior to removal. Each plunger capsule assembly must be installed in the original location during assembly.

22. Remove plunger capsule assemblies (42) and (43) from the valve body.

Show/hide table



Illustration 80	g01933231

Show/hide table



Illustration 81	g01933232

Note: Step 23 is for the disassembly of plunger capsule assembly (42) .

23. Remove the following items from plunger (44) : ring (52), seat (51), spring (50), ring (49), seat (48), retainer (47), cap (46) and spring (45) .

Show/hide table



Illustration 82	g01933235

24. Remove O-ring seal (53) and lip seal (54) from cap (46) .

25. Repeat Steps 22 through 24 for the remaining plunger capsule assembly.

Note: The valve groups for the tilt circuit and for the auxiliary circuit contain a different type of plunger capsule assembly. Step 26 and step 27 are for the disassembly of plunger capsule assembly (55).

Show/hide table



Illustration 83	g01933238

Show/hide table



Illustration 84	g01933240

26. Remove the following items from plunger (56) : ring (63), seat (62), spring (61), ring (60), seat (59), retainer (58) and cap (57) .

Show/hide table



Illustration 85	g01933245

27. Remove O-ring seal (64) and lip seal (65) from cap (57) .

Pilot Operated Hydraulic Control - Install

Installation Procedure

Show/hide table



Illustration 86	g01933434

1. Install hydraulic control valve (9) in the cab.

Show/hide table



Illustration 87	g01933435

2. Install four nuts (8) that fasten hydraulic control valve (9) to support assembly (10) .

Show/hide table



Illustration 88	g01933436

3. Connect six hose assemblies (7) .

Show/hide table



Illustration 89	g01933437

4. Connect two electrical connectors (6) .

Show/hide table



Illustration 90	g01933438

5. Install control cover (3) .

6. Install four screws (5) .

Show/hide table



Illustration 91	g01933439

7. Install two screws (4) .

Show/hide table



Illustration 92	g01991498

8. Install two screws (5) in control cover (3) .

Show/hide table



Illustration 93	g01933440
Typical Example

9. Install control cover (3). Install three screws (1) .

10. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

Parking Brake System Air - Purge

Show/hide table

Personal injury or death can result if two persons are not used in the following procedure.

Show/hide table

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Machine Preparation

1. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel. Lower the implements to the ground. Stop the engine.

2. Permit only one operator on the machine. Keep all other personnel away from the machine or in sight of the operator.

3. Engage the parking brake. Put blocks in front of the wheels and behind the wheels.

Show/hide table



Illustration 94	g01933634
Steering frame lock in the LOCKED position

4. Install steering frame lock in the LOCKED position so the machine cannot articulate.

5. Make sure that the transmission direction control lever is in theNEUTRAL position.

Show/hide table



Illustration 95	g01963133
Air purge screw for the parking brake

Note: The air purge screw is located on the left side of the parking brake housing. The air purge screw is connected directly to the parking brake.

6. Fasten one end of a transparent tube that is 6.4 mm (.25 inch) in diameter to the air purge screw. Put the other end of the tube into a suitable container for collecting the hydraulic oil. The tube may also be routed back to the hydraulic oil tank.

Test Procedure

1. Check the hydraulic tank oil level. Maintain the correct oil level in the hydraulic oil tank while the air removal procedure is performed.

2. Start the engine. Allow the oil pressure to increase to the cutout pressure.

3. Disengage the parking brake. This procedure will allow high-pressure oil to flow to the parking brake. Keep the parking brake disengaged throughout Step 8.

4. Ensure that the transparent tube is correctly routed for the collection of oil.

5. Slowly loosen the air purge screw.

6. Hydraulic oil will flow out of the air purge screw and through the clear plastic tubing.

7. Allow the oil to flow into the container until no air bubbles are visible.

8. Tighten the air purge screw.

9. Engage the parking brake.

10. Stop the engine.

11. Fill the hydraulic tank, if necessary.

Parking Brake - Manual Release

Show/hide table

Personal injury or death can result from a brake malfunction. Do not operate the machine if the parking brake was engaged due to a malfunction of the hydraulic oil system or the service brakes. Correct any problem before attempting to operate the machine.

ReferenceFor more information on preparing the machine for troubleshooting, refer to the Service Manual module for Testing and Adjusting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.

1. Block the wheels in order to keep the machine from rolling when the parking brake is disengaged.

Show/hide table



Illustration 96	g01933655
Steering frame lock in the LOCKED position

2. Install steering frame lock in the LOCKED position.

Show/hide table



Illustration 97	g01933674
Parking Brake (1) Plate. (2) Bolts (storage location). (3) Bolt holes (release).

Show/hide table



Illustration 98	g01933675
Section A-A (1) Plate. (2) Bolts. (4) Chamber. (5) Spring.

3. Remove three bolts (2) from plate (1) .

4. Install the three bolts (2) into threaded holes (3) .

5. Tighten the bolts in threaded holes (3) until solid resistance is felt. Tightening will force retainer plate (1) outward in order to release the parking brake.

6. When the manual release of the parking brake is no longer necessary, remove bolts (3) . Removing the bolts will engage the parking brake. Install the bolts in the storage locations (2) .

Parking Brake Control Cable - Adjust

Show/hide table



Illustration 99	g01933693
Parking Brake Control Assembly (Operator Control Area) (1) Parking brake control knob. (2) Nut. (3) Bracket. (4) Cable end. (5) Bulkhead nuts.

Show/hide table



Illustration 100	g01933694
Parking Brake Control Cable at the Parking Brake Control Valve (6) Lever assembly. (7) Cotter. (8) Clevis pin. (9) Rod end. (10) Nut. (11) Cable end with swivel joint. (12) Bulkhead nuts. (13) Bracket.

1. Position bulkhead nuts (5) on cable end (4) into bracket (3) .

2. Tighten bulkhead nuts (5) to a torque of 38 ± 7 N·m (28 ± 5 lb ft).

3. Thread nut (2) onto cable end (4). Thread parking brake control knob (1) onto cable end (4) .

4. Thread nut (2) against parking brake control knob (1). Tighten nut (2) to a torque of 8 ± 3 N·m (6 ± 2 lb ft).

5. Center bulkhead nuts (12) on bracket (13). Tighten bulkhead nuts (12) to a torque of 38 ± 7 N·m (28 ± 5 lb ft).

6. Extend the parking brake control cable completely at cable end (4). Keep the parking brake control cable in this position during Step 7.

7. With the parking brake cable and the parking brake linkage in the ENGAGED position, thread rod end (9) onto cable end (11). Thread rod end (9) onto cable end (11) until the hole in rod end (9) is in alignment with the hole in lever assembly (6). Turn rod end (9) clockwise for an additional ten full turns. Be sure that you align the hole in rod end (9) with the hole in lever assembly (6) .

8. If necessary, reposition bulkhead nuts (12) on bracket (13) in order to correctly position rod end (9) in Step 7.

9. Tighten nut (10) against rod end (9) to a torque of 8 ± 3 N·m (6 ± 2 lb ft).

10. Install clevis pin (8) and cotter (7) .

Steering Neutralizer Valve - Check and Adjust

1. Move the machine to a location that is smooth, level, and hard. The location should also be dry and free of debris.

2. Move steering frame lock (1) to the UNLOCKED position.

Show/hide table



Illustration 101	g01934115
Typical Example of Neutralizer Valve and Stop

3. Place a ball of putty on the rear face of the left steering stop. The diameter of ball (2) should be approximately 19 mm (.75 inches).

4. Move the transmission direction and speed control lever to the NEUTRAL position. Start the engine. Raise an empty bucket to a height of approximately 300 mm (11.8 inch).

5. Disengage the parking brake.

6. Run the engine at high idle. Turn the machine all the way to the left.

7. Steer the machine so that the machine is facing straight ahead. Engage the parking brake. Lower the bucket to the ground. Stop the engine.

8. Measure the thickness of ball (2). The putty should be pressed to a thickness of 12.7 ± 3 mm (.5 ± .12 inch).

9. Adjust the strikers, as needed. Lock the strikers in place with the locknut.

10. If necessary, repeat Steps 3 through 10 until the dimension is correct.

11. Repeat this procedure for the right turn steering stop adjustment.

Lift Kickout - Adjust

Show/hide table

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth, level surface. Lower the work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock.

Show/hide table

Personal injury or death can result from sudden movement of the lift cylinders or the tilt cylinders. Do not stand under the work tool when you are testing or adjusting the lift cylinders or the tilt cylinders. Do not stand under the lift arms when you are testing or adjusting the lift cylinders or the tilt cylinders.

Machine Preparation for Troubleshooting

1. Park the machine on a smooth, level surface. Park the machine away from working machines and personnel. Lower the work tools to the ground.

2. Allow only one operator on the machine. Keep all personnel away from the machine or in the view of the operator.

3. Engage the parking brake.

Show/hide table



Illustration 102	g01934217

4. Place the steering frame lock in the LOCKED position.

   ReferenceFor more information about preparing the machine for troubleshooting, refer to the Service Manual module Testing and Adjusting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.

Adjust the Lift Kickout

1. Start the engine. Raise the lift arms to the desired lift kickout height. Ensure that the lift arms are properly supported. Turn the engine start switch to the OFF position.

   Note: The lift kickout is located on the left side of the front frame.

Show/hide table



Illustration 103	g01934234

2. Loosen bolts (3). Adjust magnet (2) so the center of magnet (3) is aligned with the center of control group (1) .

3. Tighten bolts (3) .

Show/hide table



Illustration 104	g01934253

4. Loosen bolts (4). Adjust control group (1) so the face of control group (1) is aligned to magnet (2) with the proper gap. The gap should be 8 ± 2 mm (0.32 ± 0.08 inch).

5. Tighten bolts (4) .

6. In order to check the adjustment, start the engine. Lower the work tool to the ground. Place the lift control lever into the RAISE DETENT position.

   When the work tool reaches the adjusted height, the lift control lever should return to the HOLD position.

7. If the kickout position is not correct, perform Step 1 through Step 5 until the proper kickout height is adjusted.

Work Tool Positioner - Adjust

Show/hide table

Use caution to avoid possible personal injury when adjusting the bucket positioner. Stop the engine and lower all equipment to relieve the hydraulic pressure. Engage the parking brake and block the tires to prevent sudden movement of the machine. Keep unauthorized personnel off the machine.

1. Move the machine to a smooth horizontal location. Move away from working machines and personnel. Lower the work tools to the ground.

2. Allow only one operator on the machine. Keep all personnel away from the machine or in the view of the operator.

3. Engage the parking brake.

Show/hide table



Illustration 105	g01936935

4. Place the steering frame lock in the LOCKED position.

   ReferenceFor more information about preparing the machine for troubleshooting, refer to the Service Manual module Testing and Adjusting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.

5. Start the engine. Position the work tool at the desired angle to the ground.

   Note: For best results, position the work tool so that the bottom of the work tool is parallel to the ground.

6. Lower the work tool to the ground.

7. Turn the engine start switch key to the OFF position.

Show/hide table



Illustration 106	g01936937
(1) Bolts. (2) Tube Assembly. (3) Control Group. (4) Allen Head Screw. (5) Tilt Cylinder Pin. (6) Tilt Linkage.

8. Loosen the setscrews that secure the magnet assembly on tilt cylinder pin (5). Thread the magnet assembly into pin (5) until the magnet assembly contacts the plate. Turn the magnet assembly so that the magnet assembly is perpendicular to the tube assembly for work tool (2). Once adjusting is complete, tighten the setscrews that secure the magnet to a torque of 4 ± 1 N·m (2.9 ± 0.74 lb ft).

9. To position the tube assembly (2), loosen two bolts (1) and tighten allen head screw (4) in order to expand the clamp.

10. Position the tube assembly so that the front edge of the control group (3) on the tube assembly (2) is aligned with the front edge of the magnet on the tilt cylinder pin (5) .

11. When tube assembly (2) is correctly adjusted, loosen allen head screw (4). Tighten two bolts (1). Tighten allen head screw (4) to 15 ± 4 N·m (11 ± 3 lb ft) in order to prevent loss during normal machine operation.

12. Adjust control group (3) so the control group is vertically centered with the magnet on tilt linkage (6). Also, adjust control group (3) so there is a gap of 5.0 ± 1.0 mm (0.19 ± .04 inch) between the face of control group (3) and the magnet on tilt linkage (3) .

13. Perform the following steps in order to verify the adjustment to the positioner for the work tool.

    1. Start the engine.

    2. Raise the lift arms.

    3. Move the work tool to the full DUMP position.

    4. When the work tool reaches the preset digging angle, the tilt control lever should return to the HOLD position.

14. If the work tool positioner is not adjusted properly, perform Step 8 through Step 12 in order to achieve the desired adjustment.

Show/hide table



Illustration 107	g01936940

15. Place the steering frame lock in the STORE position.

Air Cleaner - Remove and Install

Removal Procedure

Table 5

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	2
B	138-7575	Link Bracket	2

Show/hide table



Illustration 108	g01962602

1. Remove cover (1), cover (2), and bolts (3) .

Show/hide table



Illustration 109	g01962603

2. Disconnect tube assembly (5) and clip (6) under cover (4) .

Show/hide table



Illustration 110	g01962604

Show/hide table



Illustration 111	g01962605

3. Install Tooling (A) and a suitable lifting device to cover (4). The weight of cover (4) is approximately 29 kg (65 lb). Remove prop rod (7) from the side door. Remove cover (4) .

Show/hide table



Illustration 112	g01962606

4. Disconnect hose (11), dust ejector 8, and () strip (13). Remove guard (14) .

5. Remove left guard (9). Disconnect both ends of dryer (10). Remove U-bolts (12) .

Show/hide table



Illustration 113	g01962607

6. Remove bolts (15) and clip (16) from behind mat (17) (not shown).

Show/hide table



Illustration 114	g01962608

7. Disconnect harness assembly (18), tube (19), and clip (20) .

Show/hide table



Illustration 115	g01962609
View from bottom of air cleaner

8. Remove clips (21) .

Show/hide table



Illustration 116	g01962610

9. Install Tooling (A) and Tooling (B) to the cover. Fasten a suitable lifting device to Tooling (A) and Tooling (B). Remove bolts (22) .

Show/hide table



Illustration 117	g01962614

10. Remove bolt (23). Remove the air filter assembly. The weight of the air filter assembly is approximately 68 kg (150 lb).

Show/hide table



Illustration 118	g01962615

11. Remove bolts (24) .

12. Remove bolts (25). Remove plate (26) .

13. Remove bolts (27) and air cleaner (28) .

Installation Procedure

Show/hide table



Illustration 119	g01962616

1. Install air cleaner (28). Install bolts (27) .

2. Install plate (26) and bolts (25) .

3. Install bolt (24) .

Show/hide table



Illustration 120	g01962617

Show/hide table



Illustration 121	g01962618

4. Use Tooling (A), Tooling B, and () a suitable lifting device in order to install the air filter assembly. The weight of the air filter assembly is approximately 68 kg (150 lb). Install bolt (23) .

5. Install bolts (22). Remove Tooling (A) and Tooling (B) .

Show/hide table



Illustration 122	g01962619
View from bottom of air cleaner

6. Install clips (21) .

Show/hide table



Illustration 123	g01962620

7. Connect harness (18), tube (19), and clip (20) .

Show/hide table



Illustration 124	g01962621

8. Install bolts (15) and clip (16) behind mat (17) (not shown).

Show/hide table



Illustration 125	g01962622

9. Install U-bolts (12). Connect both ends of dryer (10). Install left guard (9) .

10. Install guard (14). Connect hose (11), dust ejector 8, and () strip (13) .

Show/hide table



Illustration 126	g01962623

Show/hide table



Illustration 127	g01962624

11. Install Tooling (A) and a suitable lifting device to cover (4). The weight of cover (4) is approximately 29 kg (65 lb).

12. Install prop rod (7) and cover (4) .

Show/hide table



Illustration 128	g01962625

13. Connect tube assembly (5) and clip (6) to cover (4) .

Show/hide table



Illustration 129	g01962626

14. Install cover (1), cover (2), and bolts (3) on both sides.

The Procedure for the Calibration of the Transmission Mounted 265-5049 Parking Brake Gp

This publication will give specific instructions for the calibration of the transmission mounted 265-5049 Parking Brake Gp .

Read all instructions before you begin this procedure.

Show/hide table

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth, level surface. Lower the work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock.

Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.

Shift the transmission direction switch to the NEUTRAL. If the machine is equipped with a speed control switch, set the speed control switch to any speed position. If the machine is equipped with a direction control switch, shift the transmission into the NEUTRAL position.

Calibration

Note: This procedure may terminate if any unknown functions or any unexpected functions are activated. This procedure may terminate if a fault is present. Do not move any switch positions, any levers, or any pedals unless you are instructed differently. Clear any active fault codes for the transmission before you begin the calibration procedure. Use the AVSpare Electronic Monitoring System EMS and a 4C-8195 Control Service Tool to complete this procedure.

1. Start the engine. With the transmission in neutral and the parking brake engaged, increase the engine speed to high idle.

2. Warm the transmission oil to at least 40 °C (104 °F).

Hold Level Calibration Mode

Note: This procedure sets the hold level pressure for each clutch. Clutches one, two, three, four, and six require a hold level pressure of 137.8952 ± 20.6843 kPa (20 ± 3 psi). Clutch 5 requires a hold level pressure of 276 ± 20 kPa (40 ± 3 psi).

1. Press and hold the mode switch on the control service tool until the dash display of the EMS shows mode "8". Release the Mode switch. Once in mode "8", toggle the scroll switch until the EMS display shows the submode number of the clutch that is being calibrated.
   Show/hide table

   Table 6

   Submode	Clutch	Default value of the Hold level pressure (bits)
   41	Clutch 1	10
   42	Clutch 2	10
   43	Clutch 3	10
   45	Clutch 4	10
   45	Clutch 5	21
   46	Clutch 6	10

2. The calibration procedure will require the user to install a pressure gauge or a transducer to the clutch that is being calibrated. The gauge or the transducer can be installed at the remote pressure tap. The remote pressure tap is located behind the left-hand side of the cab under the proud profile. Use a 100 psi pressure gauge or a transducer for better results.

   Note: Allow pressure to stabilize for at least 5 seconds for accurate readings.

3. Place the directional control switch in the FORWARD position. After a period of 2 seconds, the controller will energize the desired clutch solenoid. The hold-in current will also be applied to the desired clutch solenoid.

4. Use the "Increment" or "Decrement" switches to adjust the hold level pressure. Press and release the switches until the desired hold level pressure is within the required range. Clutches one, two, three, four, and six require a hold level pressure of 137.8952 ± 20.6843 kPa (20 ± 3 psi). Clutch 5 requires a hold level pressure of 276 ± 20 kPa (40 ± 3 psi).

5. Return the direction switch to the NEUTRAL position in order to proceed to the calibration of the next clutch. Press the Scroll switch until the next desired submode number for calibration appears on the EMS display.

6. To end the Calibration Procedure, press and hold the Mode switch until the EMS runs through all the mode numbers and a blank screen appears.

Adjustment of Ramp Level

Note: Be sure that the Hold Level Calibration has been performed on all clutches before adjusting the ramp levels.

Note: Adjustment of the ramp level is intended to fine-tune the clutch fill. Adjustment will result in smoother shifts. The ramp level should be adjusted if the transmission shifts are excessively harsh.

1. Refer to chart 7. Adjust the clutch that matches the description of the problem. In some cases, multiple clutches will need to be adjusted. If adjustment is needed, start by adjusting clutches one and two and then adjust the other clutches in the number sequence.
   Show/hide table

   Table 7

   Description of problem	Adjust:
   Harsh shifts in all reverse gears	Clutch 1
   Harsh shifts in all forward gears	Clutch 2
   Harsh shifts in fourth gear (forward and reverse)	Clutch 3
   Harsh shifts in third gear (forward and reverse)	Clutch 4
   Harsh shifts in second gear (forward and reverse)	Clutch 5
   Harsh shifts in first gear (forward and reverse)	Clutch 6

2. Press and hold the mode switch on the control service tool until the dash display of the EMS shows mode "8". Once in mode "8", toggle the scroll switch until the EMS display shows the submode number of the clutch that is being calibrated.
   Show/hide table

   Table 8

   "Submode"	"Clutch to be Calibrated"	"Default Ramp Level"
   51	Clutch 1	75
   52	Clutch 2	50
   53	Clutch 3	73
   54	Clutch 4	47
   55	Clutch 5	63
   56	Clutch 6	65

3. Place the directional control switch in the FORWARD position. The screen of the EMS will display the ramp level.

4. Use the "Increment" or "Decrement" switches to adjust the ramp level.

   Note: The user must exit the mode of adjustment after each ramp level adjustment. Refer to 9.

5. When you adjust the ramp levels, start by increasing the ramp level by increments of four. Use the clutch that has been adjusted and check if the machine shifts better.

6. If the machine still shifts harshly return to the ramp level adjustment. See step 2. Then increase the ramp level by another four.

7. Repeat this process until the machine starts to shift better. If the machine does not shift better after increasing the ramp level by 16, try decreasing the ramp level by increments of four from the default ramp level.

8. Run the diagnostics for transmission problems If the machine does not shift better after decreasing the ramp level by 16.

9. To end the Calibration Procedure, shift the directional control switch back to NEUTRAL. Then press and hold the Mode switch until the EMS runs through all the mode numbers and a blank screen appears.