1.1. Introduction
2.1. Pilot Valve (Steering) - Remove
3.2. Removal Procedure
4.1. Pilot Valve (Steering) - Disassemble
5.2. Disassembly Procedure
6.1. Pilot Valve (Steering) - Assemble
7.2. Assembly Procedure
8.1. Pilot Valve (Steering) - Install
9.2. Installation Procedure
10.1. Parking Brake - Remove
11.2. Removal Procedure
12.1. Parking Brake - Disassemble
13.2. Disassembly Procedure
14.1. Parking Brake - Assemble
15.2. Assembly Procedure
16.1. Parking Brake - Install
17.2. Installation Procedure
18.1. Pilot Operated Hydraulic Control - Remove
19.2. Removal Procedure
20.1. Pilot Operated Hydraulic Control - Disassemble
21.2. Disassembly Procedure
22.1. Pilot Operated Hydraulic Control - Install
23.2. Installation Procedure
24.1. Parking Brake System Air - Purge
25.2. Machine Preparation
26.1. Test Procedure
27.1. Parking Brake - Manual Release
28.1. Parking Brake Control Cable - Adjust
29.1. Steering Neutralizer Valve - Check and Adjust
30.1. Lift Kickout - Adjust
31.1. Machine Preparation for Troubleshooting
32.1. Adjust the Lift Kickout
33.1. Work Tool Positioner - Adjust
34.1. Air Cleaner - Remove and Install
35.2. Removal Procedure
36.2. Installation Procedure
37.1. The Procedure for the Calibration of the Transmission Mounted 265-5049 Parking Brake Gp
38.2. Calibration
39.2. Hold Level Calibration Mode
40.2. Adjustment of Ramp Level
- 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
- Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
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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. |
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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. |
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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.
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Illustration 1 | g01945204 |
- Disconnect four hose assemblies (1) from the pilot valve (2) .
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Illustration 2 | g01945207 |
- 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
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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     |
- 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.
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Illustration 3 | g01945212 |
- Remove mounting bracket (1) .
- Remove check valves (2) .
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Illustration 4 | g01945213 |
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Illustration 5 | g01945215 |
- Remove bolts (3) and actuator assembly (4) .
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Illustration 6 | g01945216 |
- Loosen nut (5). Remove retainer assembly (6) .
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Illustration 7 | g01945219 |
- Remove O-ring seal (7) .
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Illustration 8 | g01945221 |
- Mark the position of the key on shaft (8) for assembly purposes. Remove pin (9) that holds actuator (10) to shaft (8) .
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Illustration 9 | g01945222 |
- Remove lip seal (11) .
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Illustration 10 | g01945223 |
- Use Tooling (A) in order to remove retainer ring (12) .
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Illustration 11 | g01945266 |
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Illustration 12 | g01945267 |
- Remove shaft assembly (8) and actuator (10) .
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Illustration 13 | g01945268 |
- Use Tooling (B) in order to remove retaining ring (14) and bearing (13) from the shaft.
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Illustration 14 | g01945272 |
- Remove bearing (15) from the cover.
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Illustration 15 | g01945275 |
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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. |
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- Measure the distance from nut face (17) to the end of sleeve (18). Record this measurement for assembly purposes.
- Loosen nut (17). Remove sleeve (18), nut (17) and plunger (19). Remove O-ring seal (16) .
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Illustration 16 | g01945276 |
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Illustration 17 | g01945277 |
- Measure the distance from the nut face to the end of the threads on stem (20). Record this measurement for assembly purposes.
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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. |
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- Remove nut (26), nut (25), retainer (24), spring (23), spring (22) and slug (21) from stem (20) .
- Repeat steps 14 through 15 for the removal of spool assembly (27) .
Pilot Valve (Steering) - Assemble
Assembly Procedure
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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.
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Illustration 18 | g01945286 |
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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. |
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- 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.
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Illustration 19 | g01945288 |
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Illustration 20 | g01945289 |
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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. |
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- Install spool assembly (20) .
- Install sleeve (18), nut (17) and plunger (19). Adjust the sleeve and the nut until the measurement that was recorded during disassembly is obtained.
- Repeat steps 1 through 3 for the installation of spool assembly (27) .
- Install O-ring seal (16) .
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Illustration 21 | g01947172 |
- Install bearing (15) in the cover.
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Illustration 22 | g01947155 |
- Use Tooling (B) in order to install bearing (13) and retaining ring (14) on the shaft.
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Illustration 23 | g01947160 |
- Install shaft assembly (8) and actuator (10) .
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Illustration 24 | g01947165 |
- Use Tooling (A) in order to install retainer ring (12) .
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Illustration 25 | g01945299 |
- 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) .
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Illustration 26 | g01945301 |
- Install lip seal (11) .
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Illustration 27 | g01945303 |
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Illustration 28 | g01945305 |
- 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.
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Illustration 29 | g01945308 |
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Illustration 30 | g01945310 |
- Install actuator assembly (4) and bolts (3). Tighten the bolts to a torque of 25 ± 6 N·m (18 ± 4 lb ft).
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Illustration 31 | g01945313 |
- Install check valves (2) .
- Install the mounting bracket (1) .
- Install the steering pilot valve. Refer to Disassembly and Assembly, "Pilot Valve (Steering) - Install".
Pilot Valve (Steering) - Install
Installation Procedure
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Illustration 32 | g01945333 |
- Install the steering pilot valve, two bolts (3) and the washer.
- Install steering shaft (5), bolt (4) and the nut.
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Illustration 33 | g01947215 |
- Connect four hose assemblies (1) to the pilot valve (2) .
- Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
Parking Brake - Remove
Removal Procedure
- Remove the cab. Refer to Disassembly and Assembly, "Cab - Remove".
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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. |
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Illustration 34 | g01932575 |
- Disconnect hose assembly (2) from parking brake (1) .
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Illustration 35 | g01932577 |
- Remove bolts (3) from plate (4) .
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Illustration 36 | g01932578 |
- Install bolt (3) in plate (4) in order to release the parking brake.
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Illustration 37 | g01932579 |
- Disconnect hose assembly (5).
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Illustration 38 | g01932582 |
- 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
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Table 3
Required Tools     |
Tool     |
Part Number     |
Part Description     |
Qty     |
A     |
1P-7405     |
Eyebolt     |
1     |
- Remove the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Remove".
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Illustration 39 | g01932597 |
- Remove springs (7) from pressure plate (8) .
- Remove pressure plate (8). Remove plates (9) and brake disc assemblies (10) .
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Illustration 40 | g01932598 |
- Remove retainer (11) and hub (12). Remove the O-ring seal.
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Illustration 41 | g01932600 |
- Remove brake shaft (13) from the bottom side of the bearing cage.
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Illustration 42 | g01932602 |
- Remove lip seal (14), retaining ring (15), and bearing (16) from the bearing cage.
Parking Brake - Assemble
Assembly Procedure
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Table 4
Required Tools     |
Tool     |
Part Number     |
Part Description     |
Qty     |
B     |
1P-0520     |
Driver Group     |
1     |
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Illustration 43 | g01932614 |
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Illustration 44 | g01932615 |
- 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.
- 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.
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Illustration 45 | g01932617 |
- Install brake shaft (13) from the bottom of the bearing cage, as shown.
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Illustration 46 | g01932619 |
- Install hub (12), the O-ring seal, and retainer (11) over the brake shaft.
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Illustration 47 | g01932620 |
- 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) .
- Install pressure plate (8). Install springs (7) .
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Illustration 48 | g01932621 |
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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. |
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- Put brake housing assembly (6) in position. Install bolts (5) that hold brake housing assembly (6) in position on the pressure plate.
- 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.
- Install spacers (3) on brake housing assembly (6) .
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Illustration 49 | g01932633 |
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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. |
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- 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).
- Install the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Install".
Parking Brake - Install
Installation Procedure
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Illustration 50 | g01933114 |
- 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) .
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Illustration 51 | g01933115 |
- Connect hose assembly (5) .
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Illustration 52 | g01933116 |
- Remove bolt (3) from plate (4) in order to engage the parking brake.
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Illustration 53 | g01933119 |
- Install bolts (3) into plate (4) .
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Illustration 54 | g01933120 |
- Connect hose assembly (2) to parking brake (1) .
Pilot Operated Hydraulic Control - Remove
Removal Procedure
- Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
- Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "System Pressure - Release".
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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. |
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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. |
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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.
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Illustration 55 | g01933153 |
Typical Example |
- Remove three screws (1) from control cover (3) .
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Illustration 56 | g01933154 |
- Remove two screws (4) from control cover (3) .
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Illustration 57 | g01991424 |
- Remove two screws (4) from control cover (3) .
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Illustration 58 | g01933155 |
- Remove four screws (5) from control cover (3) .
- Remove control cover (3) .
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Illustration 59 | g01933173 |
- Disconnect two electrical connectors (6) .
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Illustration 60 | g01933175 |
- Disconnect six hose assemblies (7) .
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Illustration 61 | g01933178 |
- Remove four nuts (8) that fasten hydraulic control valve (9) to support assembly (10) .
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Illustration 62 | g01933179 |
- Remove hydraulic control valve (9) from the cab.
Pilot Operated Hydraulic Control - Disassemble
Disassembly Procedure
- Remove the hydraulic control. Refer to Disassembly and Assembly, "Pilot Operated Hydraulic Control - Remove".
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Illustration 63 | g01933186 |
- Remove grommet (4) and pull wire through plate assembly.
- Loosen two nuts (3). Remove control rods (1) and (2) .
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Illustration 64 | g01933193 |
- Remove two boots (5) .
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Illustration 65 | g01933195 |
- Remove spring clips (7) and pins (8) .
- Remove pivot plates (6) .
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Illustration 66 | g01933196 |
- Remove two screws (9), brackets (10), and clamps (11) .
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Illustration 67 | g01933197 |
- Remove four screws (12) and plate assembly (13) .
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Illustration 68 | g01933198 |
- Mark the location of six wires in connector (14) .
- Remove wedge (15) from connector (14) .
- Carefully remove six wires from connector (14) .
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Illustration 69 | g01933199 |
- Mark the location of each body assembly.
- 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.
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Illustration 70 | g01933201 |
- Remove gaskets (18) from the body assembly.
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Illustration 71 | g01933202 |
- 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.
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Illustration 72 | g01933213 |
- 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.
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Illustration 73 | g01933215 |
- Remove two O-ring seals (29) and two fittings (30) .
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Illustration 74 | g01933217 |
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Illustration 75 | g01933218 |
- Remove two valve assemblies (31). The valve assembly includes the valve body, the spring, and the spool.
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Illustration 76 | g01933220 |
- Remove the following items from valve body (34) : O-ring seal (32), O-ring seal (33) and backup ring (35) .
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Illustration 77 | g01933223 |
- Remove pin (38) and seat (36) from spool (37) .
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Illustration 78 | g01933225 |
- Remove two caps (41) from plunger capsule assemblies (39) and (40) .
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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.
- Remove plunger capsule assemblies (42) and (43) from the valve body.
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Illustration 80 | g01933231 |
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Illustration 81 | g01933232 |
Note: Step 23 is for the disassembly of plunger capsule assembly (42) .
- Remove the following items from plunger (44) : ring (52), seat (51), spring (50), ring (49), seat (48), retainer (47), cap (46) and spring (45) .
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Illustration 82 | g01933235 |
- Remove O-ring seal (53) and lip seal (54) from cap (46) .
- 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).
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Illustration 83 | g01933238 |
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Illustration 84 | g01933240 |
- Remove the following items from plunger (56) : ring (63), seat (62), spring (61), ring (60), seat (59), retainer (58) and cap (57) .
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Illustration 85 | g01933245 |
- Remove O-ring seal (64) and lip seal (65) from cap (57) .
Pilot Operated Hydraulic Control - Install
Installation Procedure
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Illustration 86 | g01933434 |
- Install hydraulic control valve (9) in the cab.
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Illustration 87 | g01933435 |
- Install four nuts (8) that fasten hydraulic control valve (9) to support assembly (10) .
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Illustration 88 | g01933436 |
- Connect six hose assemblies (7) .
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Illustration 89 | g01933437 |
- Connect two electrical connectors (6) .
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Illustration 90 | g01933438 |
- Install control cover (3) .
- Install four screws (5) .
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Illustration 91 | g01933439 |
- Install two screws (4) .
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Illustration 92 | g01991498 |
- Install two screws (5) in control cover (3) .
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Illustration 93 | g01933440 |
Typical Example |
- Install control cover (3). Install three screws (1) .
- Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
Parking Brake System Air - Purge
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Personal injury or death can result if two persons are not used in the following procedure. |
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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. |
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Machine Preparation
- 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.
- Permit only one operator on the machine. Keep all other personnel away from the machine or in sight of the operator.
- Engage the parking brake. Put blocks in front of the wheels and behind the wheels.
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Illustration 94 | g01933634 |
Steering frame lock in the LOCKED position |
- Install steering frame lock in the LOCKED position so the machine cannot articulate.
- Make sure that the transmission direction control lever is in theNEUTRAL position.
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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.
- 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
- Check the hydraulic tank oil level. Maintain the correct oil level in the hydraulic oil tank while the air removal procedure is performed.
- Start the engine. Allow the oil pressure to increase to the cutout pressure.
- 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.
- Ensure that the transparent tube is correctly routed for the collection of oil.
- Slowly loosen the air purge screw.
- Hydraulic oil will flow out of the air purge screw and through the clear plastic tubing.
- Allow the oil to flow into the container until no air bubbles are visible.
- Tighten the air purge screw.
- Engage the parking brake.
- Stop the engine.
- Fill the hydraulic tank, if necessary.
Parking Brake - Manual Release
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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. |
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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.
- Block the wheels in order to keep the machine from rolling when the parking brake is disengaged.
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Illustration 96 | g01933655 |
Steering frame lock in the LOCKED position |
- Install steering frame lock in the LOCKED position.
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Illustration 97 | g01933674 |
Parking Brake (1) Plate. (2) Bolts (storage location). (3) Bolt holes (release). |
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Illustration 98 | g01933675 |
Section A-A (1) Plate. (2) Bolts. (4) Chamber. (5) Spring. |
- Remove three bolts (2) from plate (1) .
- Install the three bolts (2) into threaded holes (3) .
- 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.
- 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
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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. |
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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. |
- Position bulkhead nuts (5) on cable end (4) into bracket (3) .
- Tighten bulkhead nuts (5) to a torque of 38 ± 7 N·m (28 ± 5 lb ft).
- Thread nut (2) onto cable end (4). Thread parking brake control knob (1) onto cable end (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).
- Center bulkhead nuts (12) on bracket (13). Tighten bulkhead nuts (12) to a torque of 38 ± 7 N·m (28 ± 5 lb ft).
- Extend the parking brake control cable completely at cable end (4). Keep the parking brake control cable in this position during Step 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) .
- If necessary, reposition bulkhead nuts (12) on bracket (13) in order to correctly position rod end (9) in Step 7.
- Tighten nut (10) against rod end (9) to a torque of 8 ± 3 N·m (6 ± 2 lb ft).
- Install clevis pin (8) and cotter (7) .
Steering Neutralizer Valve - Check and Adjust
- Move the machine to a location that is smooth, level, and hard. The location should also be dry and free of debris.
- Move steering frame lock (1) to the UNLOCKED position.
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Illustration 101 | g01934115 |
Typical Example of Neutralizer Valve and Stop |
- 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).
- 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).
- Disengage the parking brake.
- Run the engine at high idle. Turn the machine all the way to the left.
- Steer the machine so that the machine is facing straight ahead. Engage the parking brake. Lower the bucket to the ground. Stop the engine.
- Measure the thickness of ball (2). The putty should be pressed to a thickness of 12.7 ± 3 mm (.5 ± .12 inch).
- Adjust the strikers, as needed. Lock the strikers in place with the locknut.
- If necessary, repeat Steps 3 through 10 until the dimension is correct.
- Repeat this procedure for the right turn steering stop adjustment.
Lift Kickout - Adjust
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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. |
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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. |
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Machine Preparation for Troubleshooting
- Park the machine on a smooth, level surface. Park the machine away from working machines and personnel. Lower the work tools to the ground.
- Allow only one operator on the machine. Keep all personnel away from the machine or in the view of the operator.
- Engage the parking brake.
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Illustration 102 | g01934217 |
- 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
- 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.
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Illustration 103 | g01934234 |
- Loosen bolts (3). Adjust magnet (2) so the center of magnet (3) is aligned with the center of control group (1) .
- Tighten bolts (3) .
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Illustration 104 | g01934253 |
- 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).
- Tighten bolts (4) .
- 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.
- If the kickout position is not correct, perform Step 1 through Step 5 until the proper kickout height is adjusted.
Work Tool Positioner - Adjust
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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. |
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- Move the machine to a smooth horizontal location. Move away from working machines and personnel. Lower the work tools to the ground.
- Allow only one operator on the machine. Keep all personnel away from the machine or in the view of the operator.
- Engage the parking brake.
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Illustration 105 | g01936935 |
- 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.
- 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.
- Lower the work tool to the ground.
- Turn the engine start switch key to the OFF position.
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Illustration 106 | g01936937 |
(1) Bolts. (2) Tube Assembly. (3) Control Group. (4) Allen Head Screw. (5) Tilt Cylinder Pin. (6) Tilt Linkage. |
- 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).
- To position the tube assembly (2), loosen two bolts (1) and tighten allen head screw (4) in order to expand the clamp.
- 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) .
- 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.
- 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) .
- Perform the following steps in order to verify the adjustment to the positioner for the work tool.
- Start the engine.
- Raise the lift arms.
- Move the work tool to the full DUMP position.
- When the work tool reaches the preset digging angle, the tilt control lever should return to the HOLD position.
- If the work tool positioner is not adjusted properly, perform Step 8 through Step 12 in order to achieve the desired adjustment.
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Illustration 107 | g01936940 |
- Place the steering frame lock in the STORE position.
Air Cleaner - Remove and Install
Removal Procedure
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Table 5
Required Tools     |
Tool     |
Part Number     |
Part Description     |
Qty     |
A     |
138-7573     |
Link Bracket     |
2     |
B     |
138-7575     |
Link Bracket     |
2     |
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Illustration 108 | g01962602 |
- Remove cover (1), cover (2), and bolts (3) .
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Illustration 109 | g01962603 |
- Disconnect tube assembly (5) and clip (6) under cover (4) .
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Illustration 110 | g01962604 |
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Illustration 111 | g01962605 |
- 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) .
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Illustration 112 | g01962606 |
- Disconnect hose (11), dust ejector 8, and () strip (13). Remove guard (14) .
- Remove left guard (9). Disconnect both ends of dryer (10). Remove U-bolts (12) .
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Illustration 113 | g01962607 |
- Remove bolts (15) and clip (16) from behind mat (17) (not shown).
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Illustration 114 | g01962608 |
- Disconnect harness assembly (18), tube (19), and clip (20) .
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Illustration 115 | g01962609 |
View from bottom of air cleaner |
- Remove clips (21) .
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Illustration 116 | g01962610 |
- Install Tooling (A) and Tooling (B) to the cover. Fasten a suitable lifting device to Tooling (A) and Tooling (B). Remove bolts (22) .
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Illustration 117 | g01962614 |
- Remove bolt (23). Remove the air filter assembly. The weight of the air filter assembly is approximately 68 kg (150 lb).
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Illustration 118 | g01962615 |
- Remove bolts (24) .
- Remove bolts (25). Remove plate (26) .
- Remove bolts (27) and air cleaner (28) .
Installation Procedure
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Illustration 119 | g01962616 |
- Install air cleaner (28). Install bolts (27) .
- Install plate (26) and bolts (25) .
- Install bolt (24) .
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Illustration 120 | g01962617 |
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Illustration 121 | g01962618 |
- 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) .
- Install bolts (22). Remove Tooling (A) and Tooling (B) .
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Illustration 122 | g01962619 |
View from bottom of air cleaner |
- Install clips (21) .
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Illustration 123 | g01962620 |
- Connect harness (18), tube (19), and clip (20) .
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Illustration 124 | g01962621 |
- Install bolts (15) and clip (16) behind mat (17) (not shown).
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Illustration 125 | g01962622 |
- Install U-bolts (12). Connect both ends of dryer (10). Install left guard (9) .
- Install guard (14). Connect hose (11), dust ejector 8, and () strip (13) .
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Illustration 126 | g01962623 |
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Illustration 127 | g01962624 |
- Install Tooling (A) and a suitable lifting device to cover (4). The weight of cover (4) is approximately 29 kg (65 lb).
- Install prop rod (7) and cover (4) .
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Illustration 128 | g01962625 |
- Connect tube assembly (5) and clip (6) to cover (4) .
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Illustration 129 | g01962626 |
- 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.
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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. |
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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.
- Start the engine. With the transmission in neutral and the parking brake engaged, increase the engine speed to high idle.
- 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).
- 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.
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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     |
- 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.
- 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.
- 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).
- 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.
- 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.
- 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.
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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     |
- 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.
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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     |
- Place the directional control switch in the FORWARD position. The screen of the EMS will display the ramp level.
- 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.
- 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.
- If the machine still shifts harshly return to the ramp level adjustment. See step 2. Then increase the ramp level by another four.
- 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.
- Run the diagnostics for transmission problems If the machine does not shift better after decreasing the ramp level by 16.
- 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.