GEHL RT105

MUSTANG 1050RT

Compact Track Loader

Service Manual
50950457 Rev. A 07/19

Original Instructions
 TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Contents and Use of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Machine Controls and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Machine Model and Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Indicator and Operation Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety Symbol and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mandatory Safety Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Applications with Load-Handling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Parking the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance and Service Safety Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Additional Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Crystalline Silica Exposure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transporting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Lifting the Machine with a Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Loading and Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety Decals and Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Printed in U.S.A. 1 50950457/A0719

Lifting the Machine Using a Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Loading and Transporting the Machine on a Transport Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Types of Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Lubrication Schedule/Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Filter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Hydraulic Oil Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Crankcase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

DPF Exhaust System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fuel System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Hydraulic Hose Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Travel Motor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Windshield Washer Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Printed in U.S.A. 2 50950457/A0719

Long-Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Final Shutdown / Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Engine Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Radiator/Cooler Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Air Filter Housing Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Fan Shroud Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Engine Fan Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Starter Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Engine Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Hydrostatic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Introduction/General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

General Hydraulic Service Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Hydraulic Oil Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Theory of Operation/How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Hydrostatic System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Hydrostatic Pump Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Hydrostatic Pump Drive Coupler Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Bogie Wheels Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Printed in U.S.A. 3 50950457/A0719

Track Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Track Tension Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Sprocket Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Front Idler Wheel Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Travel Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Introduction/General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

General Hydraulic Service Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Hydraulic Oil Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Hydraulic System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Main Pressure Test and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Gear Pump Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Control Valve Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Lift Solenoid Valve Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Solenoid Valve Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Tilt Solenoid Valve Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Brake Solenoid Valve Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Tilt Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Tilt Cylinder Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Lift Cylinder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Lift Cylinder Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Self-Leveling Valve Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Self-Leveling Valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Printed in U.S.A. 4 50950457/A0719

SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL. . . . . 213

Hydrostatic/Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Chassis Electrical Schematic (1 of 2) (some overlap with 2 of 2 drawing). . . . . . . . . . . . . . . . . . . . . . . 214

Chassis Electrical Schematic (2 of 2) (some overlap with 1 of 2 drawing). . . . . . . . . . . . . . . . . . . . . . . 215

ROPS/FOPS Electrical Schematic (1 of 2) (some overlap with 2 of 2 drawing). . . . . . . . . . . . . . . . . . . 216

ROPS/FOPS Electrical Schematic (2 of 2) (some overlap with 1 of 2 drawing). . . . . . . . . . . . . . . . . . . 217

Start Box Jumper Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Chassis Harness Wiring Diagram - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

ROPS/FOPS Wiring Harness Diagram - DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Door Harness Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Rear Wiper Harness Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

ROPS/FOPS Wiring Harness Diagram - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Chassis Harness Wiring Diagram - Non-DPF Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Rear Lights Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Electrical Controls System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Electrical Control System General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

CAN System Service/Computer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Operation/Controller Area Network (CAN) Functional Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . 231

CAN/Control System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Indicator Lamp Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Printed in U.S.A. 5 50950457/A0719

Control Modules and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Component Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Light Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Control Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Control Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

ROPS/FOPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Tilt ROPS/FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

ROPS/FOPS/Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

ROPS/FOPS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

Restraint Bar Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Hitch Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Floor Plate Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Crossmember Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Pivot Tube Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Pivot Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Lift/Tilt Control Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Electronic Foot Throttle Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Seat Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Control Handle Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Heater Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Programmed Display Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Operator Presence Switch Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Restraint Bar Switch Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Printed in U.S.A. 6 50950457/A0719

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Lift Arm Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Lift Arm Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Lift Arm Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Lift Arm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Lift Arm Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Fluids/Lubricants Types and Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Payloads/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Coolant Compound Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Track Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Sound Power/Pressure Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Vibration Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Printed in U.S.A. 7 50950457/A0719

Printed in U.S.A. 8 50950457/A0719
 Chapter 1
INTRODUCTION

Contents and Use of this Manual

This Service Manual provides information about •

the safe and proper service of the machine. Major Improper operation, inspection and mainte-
points of safe service are detailed in the Safety nance of the machine can cause injury or death.
chapter of this manual. Read and understand the contents of this man-
ual COMPLETELY and become familiar with the
machine before operating it.
Some illustrations in this manual may show doors,
guards and shields open or removed for illustra-
tive purposes only. BE SURE all doors, guards
and shields are in their proper operating posi-
tions BEFORE starting the engine to operate the Machine Orientation
machine.
“Right” and “left”, as described in this manual, are
Because of ongoing product improvements, infor- determined from a position sitting in the operator’s
mation included in this manual may not exactly seat and facing forward.
match the machine. Manitou reserves the right to
modify and improve products at any time without
notice or obligation. Machine Controls and Operation
The machine is provided from the factory with an Refer to the Operator’s Manual for the machine for
Operator’s Manual. A storage container is provided detailed controls and operation information.
behind the operator’s seat for storing the Operator’s
Manual. After using the manual, return it to the
storage container.

The Operator’s Manual is considered a permanent

part of the machine and should be with the machine
at all times. Replace the Operator’s Manual
promptly if it becomes damaged, lost or stolen.

Follow the instructions in the Operator’s Manual

Safety, Operation and Maintenance chapters con-
cerning accident prevention regulations, safety and
occupational regulations, and machine and traffic
regulations. Manitou is not liable for damage result-
ing from the failure to follow these regulations.

Printed in U.S.A. 9 50950457/A0719

Introduction

Component Identification

A D
G

E
B I
F

C N
H J
O

M
P L
K
K

Fig. 1 - Machine Components

Item Description Item Description

A Upright I Attachment Bracket
B Lift Cylinder J Engine Cover
C Tracks K Tail Lights
D Front Work Lights L Rear Work Lights
E Hand holds M Rear Door
F Lift Arm N ROPS/FOPS
G Auxiliary Hydraulic Couplers O Restraint Bar
H Tilt Cylinders P Lift Arm Support Device

50950457/A0719 10 Printed in U.S.A.


Machine Model and Serial
Number Locations
When ordering service parts, provide complete
information about the part and the quantity required.
Also provide the model and serial numbers of the
machine. For safety and continued proper operation,
use only genuine service parts.
Machine Model Number
_________________________________________
Machine Serial Number
_________________________________________
Fig. 2 - Machine Model/Serial Number Location
Printed in U.S.A.
Introduction
Component Serial Numbers
Engine Model Number
_________________________________________
Engine Serial Number
_________________________________________
Fig. 3 - Engine Model/Serial Number Location
Track Drive Motor Model Number
_________________________________________
Track Drive Motor Serial Number
_________________________________________
Fig. 4 - Track Drive Motor Model Number/Serial
Number Location
11 50950457/A0719
Introduction
Hydraulic Pump Model Number

_________________________________________

Hydraulic Pump Serial Number

_________________________________________

Fig. 5 - Hydraulic Pump Model Number/Serial

Number Location

ROPS/FOPS Certification Label

The ROPS/FOPS certification label is located in the
right front corner of the ROPS/FOPS ceiling.

Fig. 6 - ROPS/FOPS Certification Label Location

50950457/A0719 12 Printed in U.S.A.

 Introduction

Indicator and Operation Symbols

Power Off Power On Engine Start Battery Charge Electrical Power Engine Error Code

Worklight w/Tail Worklight Safety Alert Hazard Flasher Fasten Seatbelt Lock
Lights

Read Operator’s
Horn Volume - Full Volume - Half Full Volume - Empty Unlock
Manual

Front Window
Parking Brake Engine Air Filter Engine Oil Engine Oil Filter Engine Oil Pressure Washer

Rear Window
Fuel Filter Engine Temperature Hydraulic System Hydraulic Oil Temp. Hydraulic Oil Filter Washer

Grease Lubrication Glow Indicator Counterclockwise Front Window

Diesel Fuel Clockwise Rotation
Point Lamp Rotation Wiper

Engine Malfunction
Fast Slow Ride Control Bucket - Float
Shutdown Rear Window Wiper

Bucket - Rollback Bucket - Dump Lift Arm - Lower Lift Arm - Raise Service Hours
Beacon

Engine Speed Engine Power

Low Fuel Alarm Master Light Switch Position Lights Control Percentage Regeneration

Printed in U.S.A. 13 50950457/A0719

Introduction

Remove Key Crush Hazard Pinch Point Crush Hazard Hot Surface Hazard Regeneration Inhibit

Rotating Fan - Keep Auxiliary Hydraulics Critical Error

Safety Lock Fan Lift Arm Float
Away Flow Warning

Hitch Lock Hitch Unlock Heater Engine Temperature Pre-Heat Aftertreatment Error

Lift Point

50950457/A0719 14 Printed in U.S.A.

 Chapter 2
SAFETY
Safety Symbol and Signal Words
This manual and decals on the machine warn of
safety hazards and should be read and observed
closely.
Manitou Group, in cooperation with the Society of
Automotive Engineers, has adopted this:
This symbol is used throughout this operator’s
manual and on the decals on the machine. It iden-
tifies potential safety hazards, which, if not prop-
erly avoided, could result in injury. When you see
this symbol in this manual or on the machine, you
are reminded to BE ALERT! Personal safety is
involved!
Signal Words
•
he word “DANGER” indicates an imminently
hazardous situation, that, if not avoided, will
result in serious injury or death.
• ards that cannot be eliminated by mechanical
The word “WARNING” indicates a potentially
hazardous situation that, if not avoided, could
result in serious injury or death.
•
The word “CAUTION” indicates a potentially
hazardous situation that, if not avoided, may
result in minor or moderate injury.
Printed in U.S.A.
IMPORTANT: The word “IMPORTANT” indicates
situations that can result in possible damage to the
machine.
NOTE: The word “NOTE” indicates special or
particularly useful information.
• Before operating the machine, first read and
study the safety information in this manual. Be
sure that anyone who operates or works on the
machine is familiar with the safety precautions.
This includes providing translations of the warn-
ings and instructions for operators who are not
fluent in reading English.
• It is essential that operators be thoroughly
trained in the safe operation of the machine and
load handling. Such training should be presented
completely to all new operators and not con-
densed for those claiming previous experience.
• Operators must not be physically or mentally
impaired or under the influence of drugs or
alcohol. Do not allow minors or unqualified
personnel to operate the machine, or to be near
the machine unless they are properly supervised.
It is recommended that the operator be capable
of obtaining a valid motor vehicle operator’s
license.
• Do not use the machine for any application
or purpose other than those described in this
manual, or in manuals supplied with any attach-
ments used with the machine.
• Use of the machine is subject to certain haz-
means, but only by exercising intelligence, care
and common sense. Examples of such hazards
include but are not limited to: hillside operation,
overloading, load instability, poor maintenance,
operating too fast for conditions, and using
the machine for a purpose for which it was not
intended or designed.
• Manitou Group always takes operator’s safety
into consideration during the design process.
Guards and shields are provided, which protect
15 50950457/A0719
Safety
the operator and bystanders from moving parts
and other hazards. Operators must be alert, how-
ever, because some areas cannot be guarded or
shielded without preventing or interfering with
proper operation.
• Certain applications may require optional safety
equipment. Users must evaluate the work- site
hazards and equip the machine and the operator
as necessary. The information in this manual
does not replace any applicable safety rules and
laws. Before operating the machine, learn the
rules and laws for the local area. Make sure the
machine is equipped as required according to
these rules/laws.
• Remember that some risks to your health may
not be immediately apparent. Exhaust gases and
noise pollution may not be visible, but these
hazards can cause permanent injuries.
• Some photographs in this manual may show
doors, guards and shields open or removed for
the purposes of illustration only. Be sure all
doors, guards, shields and panels are secured in
the proper operating positions before starting the
engine to operate the machine.
• The machine is designed only for digging,
picking up, raising, transporting, and unload-
ing materials. Using the machine in any other
way is considered contrary to the intended use.
Compliance with, and strict adherence to, the
conditions of operation, service, and repair as
specified by the manufacturer, also constitute
essential elements of the intended use.
Mandatory Safety Shutdown
Procedure
BEFORE cleaning, adjusting, lubricating, fueling,
or servicing the machine, or leaving it unattended:
1. Bring the machine to a complete stop on a level
surface. If the machine must be parked on a
slope, park across the slope and chock the tracks
to prevent movement.
2. Be sure all working equipment and/or attach-
ments are stopped and the auxiliary valve is in
neutral.
50950457/A0719
3. Empty the attachment and lower the lift arm and
attachment to the ground. If the lift arm must
be left in the raised position, DO NOT leave the
operator’s position unless the lift arm support
is properly applied. See “Lift Arm Support” on
page 183.
4. Place forward/reverse drive into the neutral
position.
5. Apply the parking brake.
6. Move the throttle to the low-idle position and
allow the engine to cool.
7. Shut off the engine. Listen for evidence that
parts have stopped moving before continuing.
8. Turn the ignition key to the ON/RUN posi-
tion and move the (multi-purpose) joystick in
all directions to verify the hydraulic system is
de-pressurized.
9. Press the auxiliary hydraulics pressure relief
switch to relieve pressure in the auxiliary
hydraulics circuit.
10. Turn off the ignition.
11. Unfasten the seat belt, remove the ignition key
and take it with you. Exit the machine using the
hand-holds.
12. Always turn the battery disconnect switch to
the “OFF” position when parking the machine
inside an enclosure.
ONLY when these precautions have been taken can
you be sure it is safe to proceed. Failure to fol-
low this procedure could result in death or serious
injury.
Before Starting
• Walk around the machine and inspect it before
using it. Refer to “Pre-Start Checks” on page
73. Look for damage, loose or missing parts,
leaks, etc. Repair as required before using the
machine.
• Do not remove or modify the Roll-Over
Protective Structure/Falling Object Protective
Structure (ROPS/FOPS) unless instructed to
do so in Manitou Group-approved installation
16 Printed in U.S.A.

instructions. Modifications, such as welding,
drilling or cutting, can weaken the structure and
reduce the protection it provides. A damaged
ROPS/FOPS cannot be repaired – it must be
replaced.
• Unauthorized modifications to the machine can
cause injury or death. Never make unauthorized
modifications to any part of the machine. Any
machine modification made without authoriza-
tion from Manitou Group could create a safety
hazard, for which the machine owner would be
responsible.
• For safety reasons, use only genuine service
parts. For example, using incorrect fasteners
could lead to a condition in which the safety of
critical assemblies is dangerously compromised.
• Manitou Group equipment is designed and
intended to be used only with Manitou attach-
ments or Manitou-approved attachments. To
avoid possible personal injury, equipment dam-
age and performance problems, use only attach-
ments that are approved for use on and within
the rated operating capacity of the machine (see
“Payloads/Capacities” on page 41). Contact
your dealer or Manitou Group for information
about attachment approval and compatibility
with specific machine models. Manitou Group
cannot be responsible if the machine is used
with non-approved attachments.
• Optional kits are available through your dealer.
Because Manitou cannot anticipate, identify
and test all of the attachments owners may
want to install on their machines, please contact
Manitou Group for information on approval
of attachments, and their compatibility with
optional kits.
• Remove all trash and debris from the machine
every day, especially in the engine compart-
ment, to minimize the risk of fire.
• Always face the machine and use the hand-
holds and steps when entering and exiting the
machine. Do not jump off the machine. See
“Cab Entry and Exit” on page 75.
• Never use ether starting aids. Engine pre-heat-
ing is used for cold weather starting. Engine
Printed in U.S.A.
Safety
pre-heating can cause ether or other starting
fluid to detonate, causing injury or damage.
• Walk around the machine and inspect it before
using it. Look for damage, loose or missing
parts, leaks, etc. Repair as required before using
the machine.
• Warn all nearby personnel before starting the
machine.
• Contact the proper local authorities for utility
line locations BEFORE starting to dig. In North
America, contact the North American One-Call
Referral System at 8-1-1 in the U.S., or 1-888-
258-0808 in the U.S. and Canada.
• Below-ground hazards also include water mains,
tunnels and buried foundations. Know what is
underneath the work site before starting to dig.
• Before working near power lines (either above-
ground or buried cable type), always contact the
power utility and establish a safety plan with
them.
• If temperatures are changing, be cautious of
dark and wet patches when working or traveling
over frozen ground.
• Stay away from ditches, overhangs and other
weak support surfaces. Be sure the surrounding
ground has adequate strength to support the
weight of the machine and the load.
• The operator’s area, steps, and hand holds
must be kept free of oil, dirt, ice and unsecured
objects.
• If a lighting system is installed, check its opera-
tion before working in darkness.
• Always keep windows, lights and mirrors clean.
Poor visibility can cause accidents.
• Use warning tag/control lockout procedures
during service. Alert others that service or
maintenance is being performed by tagging the
operator’s controls, and other machine areas if
required, with a warning notice.
• NEVER start the engine if there is any indi-
cation that maintenance or service work is in
progress, or if a warning tag is attached to the
controls.
17 50950457/A0719
Safety
• Replace damaged safety decals and a lost or
damaged operator’s manual. Always store this
operator’s manual in the storage compartment
provided for it inside the cab.
• Work crew members should observe and mon-
itor terrain and soil conditions at the work site,
along with traffic, weather-related hazards and
any above- or below-ground obstacles and
hazards.
• Read the operator’s manual provided with each
attachment before using it.
• Adjust the seat to allow full actuation of all
controls. Never adjust the seat during machine
operation.
• ALWAYS wear appropriate personal protective
equipment for the job and working conditions.
Hard hats, goggles, protective shoes, gloves,
reflector-type vests, respirators, and ear protec-
tion are examples of types of equipment that
may be required. DO NOT wear loose fitting
clothing, long hair, jewelry or loose personal
items while operating or servicing the machine.
During Operation
• ALWAYS fasten the seat belt securely and prop-
erly. Never operate the machine without the seat
belt fastened around the operator.
• Only start the engine and only operate the con-
trols while seated in the operator’s seat.
• Wear safety goggles, ear, and head protection,
and any other protective clothing or equipment
as needed while servicing the machine.
• Always keep hands and feet inside the opera-
tor’s compartment while operating the machine.
• Check indicators and displays for normal condi-
tions after starting the engine. Check the oper-
ation of the controls. Listen for unusual sounds
and remain alert for other potentially hazardous
conditions.
• If the engine should stall for any reason during
operation, always turn the ignition key all the
way counter-clockwise to the “OFF” position
before re-starting the engine.
50950457/A0719
• Operator visibility is limited in certain areas;
ROPS/FOPS posts, attachments, the lift arm,
items in the cab, etc., can obstruct the operator’s
view and could mask hazards or people in the
area around the machine. It is very important
the operator is aware of these masked visibility
areas before operating the machine, especially
on busy work sites.
• To reduce the hazards posed by masked visibil-
ity areas:
• Use caution when raising or lowering attach-
ments; masked visibility areas can change
dramatically when attachments and/or the
lift arm is moved.
• Look around the machine before operating.
Objects near the machine and close to the
ground can be difficult to see from the cab.
• Always look in the direction of travel,
including reverse. A back-up alarm is not
a substitute for looking behind you when
operating the machine in reverse.
• Keep bystanders out of and away from the
work area.
• Keep the lift arm as low as possible while
traveling. See “Lift Arm Travel Position” on
page 90.
• Control the machine cautiously until fully famil-
iar with all the controls and handling.
• Carry the load low. Move the controls smoothly
and gradually, and operate at speeds appropriate
for the conditions.
• New operators must learn to operate the
machine in an open area away from bystanders.
Practice with the controls until the machine can
be operated safely and efficiently.
• Do not overload the machine. See “Payloads/
Capacities” on page 41 for load limits. Be aware
that effective operating capacity is reduced
when the machine is turned.
• Do not raise or drop a loaded bucket or attach-
ment suddenly. Abrupt movements under load
can cause serious instability.
18 Printed in U.S.A.

• DO NOT ram the lift cylinder to the end of the
stroke. The resulting jolt could spill the load.
• Do not use the machine to lift or transport
people. Never carry riders. Do not allow others
to ride on the machine or attachments, because
they could fall or cause an accident.
• Never leave the operator’s seat without lower-
ing the lift arm/attachment flat on the ground or
engaging the lift arm support device(s), and then
stopping the engine and removing the ignition
key.
• Stop the engine and place the controls in the
lock-out position before mounting attachments.
Check that attachments are securely fastened to
the lift arm before working.
• Be aware that attachments affect the handling
and balance of the machine. Adjust the oper-
ation of the machine as necessary when using
attachments.
• Before coupling or uncoupling the hydraulic
lines for the attachment, stop the engine and
press the auxiliary hydraulics pressure relief
switch to relieve pressure in the auxiliary
hydraulics circuit.
• Make sure the bucket is lowered to the ground
before activating the lift arm float. Never acti-
vate the float function with the bucket or attach-
ment raised, because this will cause the lift arm
and bucket or attachment to drop suddenly.
• Be aware of overhead obstacles. Any object near
the lift arm could represent a potential hazard,
or cause the operator to react suddenly and
cause an accident. Use a spotter or signal person
when working near bridges, phone lines, work
site scaffolds, or other obstructions.
• Use extra care on loose ground. Working heavy
loads over loose, soft ground or uneven terrain
can cause dangerous side-load conditions and
possible tip-over and injury. Traveling with a
suspended load or an unbalanced load can also
be hazardous.
• Stay away from the edges of loading docks,
ramps, ditches, excavations, retaining walls and
trenches.
Printed in U.S.A.
Safety
• Do not place limbs near moving parts. Severing
of body parts can result.
• Wear safety goggles, ear and head protection,
and any other protective clothing or equipment
as needed while operating the machine.
• Exhaust fumes can kill. Do not operate the
machine in an enclosed area without adequate
ventilation. Internal combustion engines deplete
the oxygen supply within enclosed spaces and
may create a serious hazard unless the oxygen is
replaced.
• Operators should be aware of any open win-
dows, doors or duct work into which exhaust
gases may be carried, exposing others to danger.
• Never allow anyone under a raised lift arm.
Lowering the lift arm or a falling load can result
in death or serious personal injury.
• Avoid slowing suddenly while carrying a load.
Sudden slowing can cause the load to fall off the
attachment, or cause the machine to tip over.
• Slow down the work cycle and use slower travel
speeds in congested or populated areas. Use
commonly understood signals so other members
of the work crew can warn the operator to slow
or halt work in a potentially hazardous situation.
• Use a signal person if you cannot see the entire
work area clearly, in high traffic areas and when-
ever the operator’s view is not clear.
• Stay alert for people moving through the work
area. When loading a truck, the operator should
always know where the driver is.
• To cross railroad tracks, ditches, curbs or similar
surfaces, cross perpendicularly and drive slowly.
• Exposed hydraulic hoses could react with explo-
sive force if struck by falling or overhead items.
NEVER allow hoses to be hit, bent or interfered
with during operation. Extra guards may be
required. Replace any damaged hoses.
• Do not move the lift arm or attachment during
transport. Use the hydraulics lockout button
to deactivate the lift and tilt hydraulics during
transport.
19 50950457/A0719
Safety
• Do not use the machine in an environment
where the hot muffler could present a fire haz-
ard, such as hay or straw storage facilities.
• To avoid being thrown forward and injured, do
not drive into materials at high speeds.
• Never travel over obstacles or slopes that will
cause the machine to tilt severely. Travel around
any slope or obstacle that would cause a tilt
greater than 10°.
• Avoid steeps slopes. Do not make sharp turns
on slopes. Drive up and down slopes, not across
them. Drive slowly on slopes. Keep the heavy
end of the machine pointed uphill.
• Avoid sharp turns and high speeds while carry-
ing loads, especially on slopes. The stability of
the machine is reduced during sharp turns, and
the load may shift, greatly increasing the possi-
bility of an rollover.
• Do not raise the safety bars/armrests while trav-
eling. Raising the safety bars/armrests applies
the parking brake, which can cause the machine
to tip forward.
• Do not turn off the ignition switch while travel-
ing. Turning off the ignition will cause sudden
braking, which may cause loss of control, injury
and/or tipping of the machine.
• Be sure no one enters the work area of the
machine. Anyone near the machine is at risk of
being injured.
• Unless necessary for servicing the machine,
the engine hood must not be opened while the
engine is running.
• In cold weather, avoid sudden travel movements
and stay away from even slight slopes. The
machine can slide sideways on icy slopes.
• Snow accumulation can hide potential hazards.
Use care while operating and while using the
machine to clear snow.
• If the machine becomes damaged or malfunc-
tions, stop the machine immediately and lock
and tag it. Repair the damage or malfunction
before using the machine again.
50950457/A0719
• Never jump off the machine. Always leave the
machine using the steps and hand-holds. Never
get on or off a moving machine.
• If unable to exit out the front of the cab, remove
the rear window by pulling the emergency rear
window release triangle until the window seal is
pulled out of the window frame, then push the
window out of the frame.
Applications with Load-Handling
Devices
• Specific procedures are required, when using
load-handling devices (e.g., slings, chains)
for transporting and placing loads. For exam-
ple, assistance from other people is needed
when lifting and lowering pipes, culverts or
containers:
• The machine may only be used with
load-handling devices if the necessary safety
devices are in place and functional.
• The load must be secured to prevent it from
falling or slipping.
• Persons guiding the load must stay in visual
contact with the operator.
• The operator must guide the load to the
ground as soon as possible while staying
out from under the loader, load and out of
harm’s way. Avoid any rotating or swinging
movements. Tag lines may be required.
• The machine may be moved with a raised
load only if the path of the machine is level.
• Persons attaching or securing loads may
only approach the machine from the side,
after the operator has given permission. The
operator may only give permission after the
machine and the attachment are stationary.
• Do NOT use any lifting attachments (slings,
chains) that are damaged or of inadequate
rated capacity.
20 Printed in U.S.A.

Parking the Machine
• When shutting down the machine for the day,
plan ahead so the machine will be on a firm,
level surface away from traffic and away from
high-walls, cliff edges and any area of potential
water accumulation or runoff. Lower the attach-
ment and lift arm to the ground. There should
be no possibility of unintended or accidental
machine movement.
• If the machine must be parked on a slope, park
across the slope and chock the tracks to prevent
movement.
• To avoid collisions when parking on streets, use
barriers, caution signs, lights, etc., so that the
machine can be easily seen at night.
• After the machine has been parked prop-
erly, shut down the machine according to the
“Mandatory Safety Shutdown Procedure” on
page 18.
Electrical Energy
• Stay away from high-voltage lines.
Electrocution can result from contact or proxim-
ity to high-voltage electric lines. The machine
does not have to make physical contact with
power lines for current to be transmitted. Use
a spotter and hand signals to keep away from
power lines not clearly visible to the operator.
• If the machine comes into contact with a live
wire:
• Do not leave the machine.
• If possible, drive the machine out of the
danger area.
• Warn others not to approach or touch the
machine.
• Have the live wire de-energized.
• Do not leave the machine until the wire has
been safely de-energized.
• Depending upon the voltage in the power line
and atmospheric conditions, strong electric
shocks can occur if the machine is closer than 3
m (10 ft.) from the power line. Higher voltages
Printed in U.S.A.
Safety
and rainy weather can further increase the safe
operating distance.
• Work on the machine’s electrical system must
be performed only by trained technicians.
• Inspect and check the machine’s electrical
equipment at regular intervals. Problems found,
such as loose connections or scorched cables,
must be repaired before using the machine.
• Only use proper, original equipment fuses/cir-
cuit breakers with the specified current rating.
Turn off the machine immediately if there is
any indication of a problem with the electrical
system.
• If the LCD is broken, care must be taken with
any leaking fluid. If LCD fluid gets on your
skin, wipe with a cloth and wash the area with
mild soap and water. If LCD fluid gets into your
eyes, thoroughly rinse your eyes with clean
water for several minutes and seek medical
assistance. If LCD fluid is swallowed, rinse your
mouth thoroughly with clean water, then drink a
substantial volume of water and induce vomit-
ing. Then seek medical assistance.
Maintenance and Service Safety
Practices
• Only trained and authorized personnel, with a
full awareness of safe procedures, should be
allowed to operate or perform maintenance or
service on the machine.
• Use warning tag/control lockout procedures
during service. Alert others that service or
maintenance is being performed by tagging the
operator’s controls — and other machine areas
if required — with a warning notice.
• Always lower lift arm or elevated items, or
securely support/secure them, before performing
any maintenance or service on the machine.
• Use solid support blocking. Never rely on jacks
or other inadequate supports when maintenance
work is being done. Never work under any
equipment supported only by jacks.
21 50950457/A0719
Safety
• Do not use the lift or tilt hydraulics to lift or
support the machine for maintenance or service.
• Always close the swing-out cab door (if
equipped) before tilting the ROPS/FOPS.
• Stay clear from underneath the ROPS/FOPS as
it is tilted.
• Always secure the ROPS/FOPS in the tilted
position with the tilt support. Never allow any-
one under the ROPS/FOPS if the securing pin is
not in place.
• Check ROPS/FOPS tilt component condition
at regular intervals. Replace damaged or worn
parts immediately.
• Always secure the ROPS/FOPS to the chassis
with anchor bolts and washers before driving or
using the machine.
• NEVER allow person(s) under the raised lift
arm and /or do not exit the machine if the lift
arm is raised unless the lift arm support is
properly applied. Refer to “Lift Arm Support”
on page 271. Disconnecting or loosening any
hydraulic connections, parts failure, and hydrau-
lic pressure venting all can cause the lift arm to
drop.
• Keep fuel and other fluid reservoir caps tight.
Do not start the engine until caps have been
secured.
• Never attempt to bypass the keyswitch to start
the engine. Use only the proper jump-starting
procedure according to the jump-starting proce-
dure in the “Operation” section in the Operator’s
Manual.
• Never use hands to search for hydraulic oil
leaks. Instead, use a piece of paper or cardboard.
Escaping fluid under pressure can be invisi-
ble and can penetrate the skin, causing serious
injury. If any fluid is injected into your skin,
see a doctor immediately. Injected fluid must be
surgically removed by a doctor or gangrene may
result.
• Always wear safety glasses with side shields
when striking metal against metal. In addition,
it is recommended that a softer (chip-resistant)
material be used to cushion the blow, otherwise,
50950457/A0719
serious injury to the eyes or other parts of the
body could result.
• Use care when seating retainer pins — retainer
pins can fly out or splinter when struck and
could cause injury.
• Do not smoke or have any spark- or flame-pro-
ducing equipment or materials in the area while
filling the fuel tank or working on the fuel or
hydraulic systems.
• Do not attempt to loosen or disconnect any
hydraulic lines, hoses, fittings, covers or caps
without first relieving hydraulic circuit pres-
sure. Relieve hydraulic pressure by performing
the “Mandatory Safety Shutdown Procedure”
on page 18 and slowly loosening the hydraulic
reservoir filler cap. Be careful not to touch any
hydraulic components that have been in recent
operation. Failure to heed this warning could
result in severe burns.
• Do not attempt to remove the radiator cap after
the engine has reached operating temperature
or if it is overheated. At operating temperatures,
engine coolant is extremely hot and under pres-
sure. Always wait for the engine to cool before
attempting to relieve pressure and remove the
radiator cap. Failure to heed this warning could
result in severe burns.
• Refer to the parts manual for information about
assembly of components. Always use the cor-
rect parts and the proper torques — incorrect
fastener connections can dangerously weaken
assemblies.
• Exhaust fumes can kill. Do not operate the
machine in an enclosed area unless there is ade-
quate ventilation.
• Operators should also be aware of any open
windows, doors or duct work into which exhaust
gases may be carried, exposing others to danger.
• Do not run the engine if repairs are being per-
formed alone. There should always be at least 2
people present if the engine must be run during
service. Both persons must maintain visual con-
tact with each other. Keep a safe distance away
from all rotating and moving parts.
22 Printed in U.S.A.
 Safety
• Always use proper tools while working on the manufacture (month or quarter and year) is
machine. Incorrect tools could break or slip, indicated on the hydraulic hoses.
causing injury, or they may not adequately per-
• Keep mounting brackets and hose and cable
form intended functions.
routing straps tight. Hose routing should have
• Unless necessary for servicing the machine, do gradual bends.
not open the engine cover while the engine is
• After cleaning the machine, examine all fuel,
running.
lubricant and hydraulic oil lines for leaks, chafe
• Do not use the machine when maintenance is marks and damage. Tighten any loose connec-
scheduled to be performed. Postponing main- tions and repair or replace parts as necessary.
tenance can result in a serious reduction of the IMPORTANT: When washing the machine using
service life of the machine, more serious and water, do not direct the water onto any electrical
costly equipment failures, and contribute to connection, electrical component, or electronic
unsafe operating conditions. component. Water may cause malfunction or dam-
• Do not work on hot engines, cooling systems or age. Power washing or other high-pressure jets
may cause physical damage.
hydraulic systems. Wait for the engine to cool.
When engine lubrication oil, gearbox lubricant • Hydraulic lines and hoses must be routed and
or other fluids require changing, wait for fluid fitted properly. Make sure no connections are
temperatures to decrease to a moderate level interchanged.
before removing drain plugs.
• When handling oil, grease and other chem-
NOTE: Temperatures below 49°C (120°F) will ical substances, follow the product-related
reduce the chances of scalding exposed skin while safety requirements Material Safety Data
allowing the fluid to drain quickly and completely. Sheet (MSDS) carefully to prevent burning or
Do not let the fluid fully cool, because drain time will
scalding.
be substantially increased.
• When washing the machine using water, do not
• Dispose of all oils and fluids properly. Used
direct the water onto any electrical connection,
oils/fluids are environmental contaminants and
electrical component, or electronic component.
may only be disposed of at approved collection
Water may cause malfunction or damage. Power
facilities. Never drain any oils/fluids onto the
washing or other high-pressure jets may cause
ground, dispose of in municipal waste collection
physical damage.
containers, or in metropolitan sewer systems or
landfills. Check state and local regulations for
other requirements.
• All safety equipment must be maintained so it is
always in good condition.
• Safety-critical parts must be periodically
replaced. Replace the following potentially
fire-related components as soon as they begin to
show signs of deterioration:
• Fuel system flexible hoses, fuel tank over-
flow drain hose and the fuel filler cap.
• Hydraulic system hoses, especially the pump
outlet lines. Replace hydraulic hoses every
6 years from the date of manufacture, even
if they do not appear damaged. The date of

Printed in U.S.A. 23 50950457/A0719

Safety
Battery Hazards
• Use the battery disconnect switch, or disconnect
the negative battery cable from the negative
battery terminal, before performing electrical
service or electrical welding on the machine.
• Do not use a battery when the fluid level is
below the minimum level. Doing so will hasten
the deterioration of the battery and shortens
battery life, and can also cause rupturing or
explosion.
• Turn off all electrical equipment before con-
necting leads to the battery, including electrical
switches on the battery charger or jump-starting
equipment.
• When disconnecting at the battery terminals,
remove the cable connected to the negative
terminal first. When installing a battery, connect
the positive terminal cable first.
• Connect the positive (+) cable first when install-
ing jumper cables. The final cable connection,
at the metal frame of the machine being charged
or jump-started, should be as far away from the
battery as possible. Disconnect the negative (-)
cable first when removing jumper cables.
• Sparks and open flames can ignite explosive
battery gas from incidental contact or static
discharge. Turn off all switches and the engine
when working on batteries. Keep battery termi-
nals tight. Contact between a loose cable clamp
and a terminal post can create an explosive
spark.
• When jump-starting from another machine, do
not allow the machines to touch. Wear safety
glasses or goggles when battery connections are
made.
• Never jump-start the machine if it has a fro-
zen battery. The battery could explode. Thaw
a frozen battery before charging it or attaching
jumper cables.
• Flush eyes with water for 10-15 minutes if
battery acid is splashed in the face. Anyone
swallowing battery acid must have immediate
medical aid. Call the Poison Control Center at
1-800-222-1222 in the United States.
50950457/A0719
Fire Hazards
• The machine must be cleaned on a regular basis
to avoid the buildup of flammable debris, such
as leaves, straw, etc. Accumulated debris, partic-
ularly in the engine compartment, creates a fire
hazard.
• It is extremely important to avoid circumstances
where explosive dust or gases can be ignited by
arcs, sparks or heat:
• Under normal operating conditions, compo-
nents on the machine operate at high tem-
perature, primarily the engine and exhaust
systems.
• If damaged or not properly maintained, the
electrical system can arc or produce sparks.
• It is recommended that a 2.27 kg (5 lb.) or
larger, multi-purpose “A/B/C” fire extinguisher
be mounted in the cab. Check the fire extin-
guisher periodically and be sure that work crew
members are trained in its use.
• Add fuel, oil, antifreeze, and hydraulic oil to
the machine only in a well ventilated area. The
machine must be parked with controls, lights
and switches turned off. The engine must be
turned off before refueling or performing service
checks.
• Do not smoke while filling the fuel tank, while
working on the fuel or hydraulic systems, or
while working around the battery.
• Always immediately replace the fuel filler cap
after refueling. Keep fuel and other fluid reser-
voir caps tight. Do not start the engine until caps
have been secured.
• Avoid spilling combustible fluids, such as oil or
fuel, on a hot engine.
• Static electricity can produce dangerous sparks
at the fuel-filling nozzle. Do not wear polyes-
ter, or polyester-blend clothing while fueling.
Before fueling, touch the metal surface of the
machine away from the fuel fill to dissipate
any built-up static electricity. Do not re-enter
the machine but stay near the fuel filling point
during refueling to minimize the build-up of
static electricity. Do not use cell phones while
24 Printed in U.S.A.
 Safety
fueling. Make sure the static line is connected Crystalline Silica Exposure
from the machine to the fuel truck before fuel-
ing begins. Exposure to crystalline silica (found in sand, soil
and rocks) has been associated with silicosis, a
• Ultra-Low Sulfur Diesel (ULSD) poses a greater debilitating and often fatal lung disease. Comply
static ignition hazard than earlier diesel formula- with all applicable rules and regulations for the
tions. Avoid death or serious injury from fire or work place. Wear approved respiratory protection
explosion; consult with your fuel or fuel system or use water spray or other means if there is no
supplier to ensure the entire fuel delivery sys- other way to control the dust.
tem is in compliance with fueling standards for
proper grounding and bonding practices. A Silica rule “29 CFR 1929.1153” by the U.S.
• Oil from leaks can ignite on hot components. Occupational Safety and Health (OSHA) indicates
Repair any damaged or leaking components a significant risk of chronic silicosis for workers
before using the machine. exposed to inhaled crystalline silica over a working
lifetime. Refer to the rule for more information
regarding exposure limits and hazard prevention.
Additional Safety Equipment
• Certain operations require use of additional
safety equipment. Install additional safety
equipment if conditions require. For example,
when using a hydraulic breaker, a polycarbonate
front window may be required.
• Never attempt to alter or modify the protective
structure by drilling holes, welding or re-locat-
ing fasteners. Any serious impact or damage to
the system requires a complete integrity re-eval-
uation, and the replacement of the system may
be necessary. Transporting the Machine
• Laminated glass or polycarbonate protection Obey federal, state and local over-the-road reg-
for the front, side or rear windows may also ulations. Check restrictions regarding weight,
be required, depending upon particular work height, width and length of a load. The hauling
conditions. vehicle, trailer and load must all be in compliance
with applicable regulations. See “Loading and
• Contact your dealer for available safety guards Transporting the Machine” on page 26.
if there is any risk of objects striking the opera-
tor’s cab.

Printed in U.S.A. 25 50950457/A0719

Safety
Lifting the Machine with a Crane
Only lift the machine according to the following
guidelines:
• The crane and rigging equipment must have
sufficient capacity. See “Weights” on page 305.
• Secure the machine against unintentional move-
ment. Use taglines as needed.
• Do not lift the machine with persons on or in the
machine.
• Any person guiding the crane operator must be
within sight or sound of the crane operator.
• Lift the machine only with the standard bucket
installed, with the bucket empty and in the
transport position.
• Persons must stay clear of, and not under, the
machine when it is lifted.
• Fasten the rigging equipment so the machine is
horizontal when it is lifted.
• Do not lift the machine by the cab. Attach the
rigging equipment only at the lift points identi-
fied by this symbol:
Fig. 7 - Lift Point Icon
50950457/A0719
Loading and Transporting the
Machine
Obey federal, state and local over-the-road regula-
tions. Check restrictions regarding weight, height,
width and length of a load. The hauling vehicle,
trailer and load must all be in compliance with
applicable regulations.
• Load and transport the machine according to
“Loading and Transporting the Machine” on
page 26.
• The transport vehicle must support the height,
width, length and weight of the machine. See
“Dimensions” on page 302 and “Weights” on
page 305.
• Remove any dirt, snow or ice from the tracks on
the machine, and from the loading ramps and
transport platform, to prevent slipping.
• Secure the machine to the transport vehicle
according to “Loading and Transporting the
Machine” on page 26 to prevent unintentional
movement.
Safety Decals and Locations
• The machine has decals that provide safety
information and precautions. These decals must
be kept legible. If missing or illegible, they must
be replaced promptly. Replacements can be
obtained from Manitou Group.
• Refer to the Parts Manual for decal part num-
bers and ordering information.
26 Printed in U.S.A.
 Safety
New Decal Application
• Surfaces must be free of dirt, dust, grease and
foreign material before applying the decal.
Remove the smaller portion of the decal back-
ing paper and apply the exposed adhesive to the
clean surface, maintaining proper position and
alignment. Peel the rest of the backing paper
and apply hand pressure to smooth out the decal
surface. Refer to the following pages for proper
decal locations.
• If replacing a part that has a decal on it, ensure
that the replacement part has the same decal.

F
K
G

V
R S B
B O
P
Q
M E

B B
C

J A D

Fig. 8 - Safety Decal Locations

Printed in U.S.A. 27 50950457/A0719

Safety

H
T
U

I
N

Fig. 9 - Safety Decal Locations - Cab

50950457/A0719 28 Printed in U.S.A.

 Safety
ANSI-Style Decals
Ref Decal Information
Located inside the engine compartment.
Warning Decal
WARNING: ROTATING FAN / HOT SURFACES
A
• Keep hands out or stop engine.
• Do not touch hot engine or hydraulic system parts.

Located inside the engine compartment

Warning Decal
WARNING: AVOID INJURY OR DEATH

• Keep safety devices working.

• Jump start per Operator’s Manual procedure.
• Keep guards, screens and windows in place.

B • Do not smoke while fueling or servicing machine.

• Clean debris from engine compartment daily to
avoid fire. Keep fire extinguisher nearby.
• Do not use hand to find hydraulic leaks. Escaping
oil under pressure can be invisible and penetrate
skin.
• Allow radiator to cool before removing cap.
Loosen cap slowly to avoid burns.

Located on the bottom of the ROPS / operator’s plat-

form and to the left of the rear cab window just above
the ROPS tilt lock.
Read Operator’s Manual Decal
WARNING

C
• Be sure lock mechanism is securely engaged
before working under ROPS.
• Read instructions for use in Operator’s Manual.

Printed in U.S.A. 29 50950457/A0719

Safety

Ref Decal Information

Located by the floor pan inside the cab, and on the
manual box cover behind the operator’s seat.
Read Operator’s Manual Decal
WARNING: AVOID INJURY OR DEATH

• Read Operator’s Manual and all safety signs

before using machine.
D
• The owner is responsible to ensure all users are
instructed on safe use and maintenance.
• Check machine before operating. Service per
Operator’s Manual.
• Contact dealer (or manufacturer) for information
and service parts.

50950457/A0719 30 Printed in U.S.A.

 Safety

Ref Decal Information

Located by the door sill inside the cab.
Operator Danger/Warning Decal
DANGER: AVOID INJURY OR DEATH
• ALWAYS wear seatbelt.
• Keep out from under lift arm unless lift arm is sup-
ported (refer to “Lift Arm Support” on page 84).
• Operate only from operator’s seat.
• Look in direction of travel. Keep children and
bystanders away.
• No riders! Never use work tools as a work
platform.
WARNING: Always follow “Mandatory Safety
Shutdown Procedure”
1. Lower equipment to the ground.
2. Reduce throttle, stop engine.
3. Apply park brake; remove key.
4. Check safety interlocks.
WARNING: AVOID OVERTURN
E

• Carry load low.

• Do not exceed Rated Operating Capacity (refer to
“Payloads/Capacities” on page 36).

Printed in U.S.A. 31 50950457/A0719

 Safety

Ref Decal Information

Located on the lift arm lift support device.
Keep Out From Under Lift Arm Decal
DANGER
DANGER Hose removal or coponent failure can cause lift arm to drop.
Always use lift arm support device when leaving lift arm raised for service.
137637

• Hose removal or component failure can cause lift

F
arm to drop.
• Always use lift arm support device when leav-
ing lift arm raised for service (refer to “Lift Arm
Support” on page 84.)

Located on the top of the attachment mounting plate.

WARNING
AVOID INJURY OR DEATH
Before operating with attachment,
check engagement of loader Attachment Lock Warning Decal
attachment bracket locking pin
to the attachment.
137755

Quick Attach System Attachment Lock WARNING: AVOID INJURY OR DEATH

WARNING
G OR DEATH
AVOID INJURY
Before operating with attachment,
check engagement of loader
attachment bracket locking pin
to the attachment.
Before operating with attachment, check engage-137755

ment of loader attachment bracket locking pin to the

Power-A-Tach® System Attachment Lock attachment.

139107 139109

Located by the floor pan inside the cab.

Avoid Injury or Death Decal
WARNING •
WARNING: AVOID INJURY OR DEATH
Inspect work area; avoid all hazards.
AVOID INJURY OR DEATH
Inspect work area; avoid all hazards. • Operate only in well ventilated area.
H Operate only in well ventilated area.
Wear any needed Personal Protective Equipment. • Wear any needed Personal Protective Equipment.
Keep away from electric power lines; avoid contact.
Do not wear loose clothing while operating or servicing machine. • Keep away from electric power lines; avoid
275635
contact.
• Do not wear loose clothing while operating or
servicing machine.

50950457/A0719 32 Printed in U.S.A.


Ref Decal
I
J
WARNING
This product can expose you
to lead which is known to the
State of California to cause
K cancer and birth defects or
other reproductive harm.
For more information go to
www.P65Warnings.ca.gov
50302796
Printed in U.S.A.
Safety
Information
Located inside the engine compartment
IMPORTANT Decal
• Do not use ether or other starting fluids to start this
engine – warranty may be voided.
Located next to the fuel filler neck
IMPORTANT Decal
DIESEL FUEL REQUIREMENTS
• Use only Ultra-Low Sulfur Diesel (ULSD) fuel.
• Use of diesel fuel with more than 15 PPM of sul-
fur will damage the engine.
Located by the floor pan inside the cab.
WARNING Decal
• This product can expose you to lead which is
known to the State of California to cause cancer
and birth defects or other reproductive harm.
• For more information go to www.P65Warnings.
ca.gov
33 50950457/A0719
Safety
ISO-Style Decals
Ref Decal Information
Located inside the engine compartment.
Warning Decal
WARNING: ROTATING FAN / HOT SURFACES
A
• Keep hands out or stop engine.
• Do not touch hot engine or hydraulic system parts.

Located inside the engine compartment

Warning Decal
WARNING: AVOID INJURY OR DEATH

• Read the Operator’s Manual before performing

any maintenance on the machine.
• Do not smoke while fueling or servicing machine.
Keep sparks and open fames away from the engine
compartment to avoid fire.
• Keep fire extinguisher nearby.
B
• Never attempt to bypass the keyswitch to start the
engine. Use only the proper jump-starting proce-
dure according to the Operator’s Manual.
• Do not use hand to fi nd hydraulic leaks.
• Escaping oil under pressure can be invisible and
penetrate skin.
• Allow radiator to cool before removing cap.
• Loosen cap slowly to avoid burns.

Located on the bottom of the ROPS / operator’s plat-

form and to the left of the rear cab window just above
the ROPS tilt lock.
Read Operator’s Manual Decal
WARNING

C
• Be sure lock mechanism is securely engaged
before working under ROPS.
• Read instructions for use in Operator’s Manual.

50950457/A0719 34 Printed in U.S.A.

 Safety

Ref Decal Information

Located by the floor pan inside the cab, and on the
manual box cover behind the operator’s seat.
Read Operator’s Manual Decal
WARNING: AVOID INJURY OR DEATH

• Read Operator’s Manual and all safety signs

D before using, maintaining or servicing the
machine.
• The owner is responsible to ensure all users are
instructed on safe use and maintenance.
• Contact dealer (or manufacturer) for information
and service parts.

Located by the door sill inside the cab.

Operator Danger/Warning Decal
DANGER: AVOID INJURY OR DEATH
• Look in direction of travel. Keep children and
bystanders away.
• ALWAYS wear seatbelt.
• Keep out from under lift arm unless lift arm is sup-
ported (refer to “Lift Arm Support” on page 84).
• Operate only from operator’s seat.
• No riders! Never use work tools as a work
platform.
WARNING: Always follow “Mandatory Safety
E Shutdown Procedure”
1. Lower equipment to the ground.
2. Reduce throttle, stop engine.
3. Apply park brake; remove key.
4. Check safety interlocks.
WARNING: AVOID OVERTURN
• Travel up and down slopes with heavy end uphill.
• Carry load low.
• Read instructions for use in Operator’s Manual.
• Do not exceed Rated Operating Capacity (refer to
“Payloads/Capacities” on page 36).
• Avoid steep slopes and high speed turns.

Printed in U.S.A. 35 50950457/A0719

 Safety

Ref Decal Information

Located on the lift arm lift support device.
Keep Out From Under Lift Arm Decal
DANGER

• Keep out from under lift arm unless lift arm is

F
supported.
• Always use lift arm support device when leav-
ing lift arm raised for service (refer to “Lift Arm
Support” on page 84).

Quick Attach System Attachment Lock Located on the top of the attachment mounting plate.
Attachment Lock Warning Decal
WARNING WARNING: AVOID INJURY OR DEATH
AVOID INJURY OR DEATH
Before operating with attachment,
check engagement of loader
attachment bracket locking pin
to the attachment.
G 137755

Before operating with attachment, check engage-

Power-A-Tach® System Attachment Lock ment of loader attachment bracket locking pin to the
attachment.

139107 139109

Located by the floor pan inside the cab.

Avoid Injury or Death Decal
WARNING: AVOID INJURY OR DEATH
• Read Operator’s Manual and all safety signs
before using, maintaining or servicing the
machine.
H
• Inspect work area; avoid all hazards.
• Operate only in well ventilated area.
• Keep away from electric power lines; avoid
contact.
• Wear any needed Personal Protective Equipment.
Located inside the engine compartment
IMPORTANT Decal

I
• Do not use ether or other starting fluids to start this
engine – warranty may be voided.

50950457/A0719 36 Printed in U.S.A.

 Safety

Lifting the Machine Using a
Crane
The crane and the lifting gear must be adjusted
to the proper dimensions. Always lift the
machine so it is horizontal when it is raised.
7. Connect spreader bar and chains to front and
rear lift points as shown. The spreader bar
length should allow for the lift chains to be
as vertical as possible during lifting. The lift-
ing chain lengths should allow for lifting the
machine as level as possible.

Make sure the crane and the lifting gear (cables,

chains) have sufficient load-bearing capacity.
The crane and the lifting gear must be adjusted
to the proper dimensions.

Secure the machine against unintentional

movement!

Keep clear of suspended loads.

Never lift with anyone in or on the machine.

Securely fasten the lifting gear to the machine

at the designated lift points.

The crane lifting crew must include experienced

crane operators only.

Lift the machine only with no attachments, with

the exception that the standard bucket can Fig. 10 - Crane Handling
remain attached. The bucket must be empty
and the lift arm lowered. 8. Carefully raise the machine, keeping it as level
as possible.

Crane Lifting Preparation

IMPORTANT: Crane handling requires lifting gear
with a spreader bar with 4 ropes, chains, etc.
1. If a bucket is attached, make sure it is emptied.
Tilt the bucket back.
2. Lower the lift arm.
3. Raise the arm rests/safety bars to apply the park-
ing brake and lock out the hydraulic functions.
4. Turn off the engine and remove the ignition key.
5. If equipped, close and lock the cab door. Do not
allow anyone to stay in the cab.
6. Close all compartment doors and the engine
cover.
Do not fasten the lifting gear to the cab to crane
lift twhe machine.

Printed in U.S.A. 37 50950457/A0719

Safety
Loading and Transporting the
Machine on a Transport Vehicle
WARNING
Do not exceed the transport vehicle’s gross
weight rating and the gross axle weight rating
when loading and transporting the machine The
transport vehicle must have sufficient capac-
ity for the size and weight of the machine. See
“Payloads/Capacities” on page 304.
Make sure the load does not fall short of the
minimum axle load of the steering axle, other-
wise the transport vehicle’s steering could be
seriously affected.
Remove any mud, snow or ice from the tracks
on the machine to prevent slipping.
Position the machine at the lowest possible
position on the transport platform, with the
center of gravity of the load over center line of
the transport vehicle. Distribute partial loads to
ensure an even load on the axles on the trans-
port vehicle.
Secure the machine properly so it cannot slip,
slide, roll, tip over or fall, or cause the transport
vehicle to tip over under transport conditions.
Use anti-slip bases and linings, load-securing
straps and chains, clamping beams, protective
pads, nets, edge protectors, etc. as needed to
properly secure the load. Consider all possi-
ble transport conditions such as: heavy brak-
ing, evasive maneuvers, and uneven or rough
roadways.
Adjust transport speed to the load, to the road/
traffic conditions and to the handling of the
transport vehicle.
Always use the proper tie-down points when
using straps and chains. See “Component
Identification” on page 28.
50950457/A0719
Loading and Securing the Machine
WARNING
Secure the loading ramps to the transport vehi-
cle before loading. Position the loading ramps
at the shallowest possible angle. Do not exceed
an angle of 15°. Only use ramps with anti-skid
surfaces.
Make sure the loading area is clear and access
to it is not obstructed.
Make sure the driver of the transport vehicle
knows the overall height, width and weight
of the vehicle, including the loaded machine,
before starting transport.
Know and follow the legal transport regulations
for the area in which the transport will occur.
Make sure the loading ramps are free of mud,
oil, grease, snow, ice, etc.
Know and follow the legal transport regulations
for the area in which the transport will occur.
30°
30864brampe.eps
Fig. 11 - Loading Ramp Placement
1. Check the engine oil. The oil level must be at
the “MAX” mark on the dipstick. Add oil if
needed.
IMPORTANT: When loading and driving on
ramps, the engine can be damaged if the engine oil
level is too low.
2. Start the engine.
3. Raise the hitch plate/attachment enough so that
it will not touch the loading ramps.
38 Printed in U.S.A.
 Safety
4. Slowly and carefully drive the machine in
reverse onto the transport vehicle, with the
bucket end facing down the ramp.
5. Do not adjust travel direction while traveling on
the ramps. Instead, drive down off of the ramps,
and re-align the machine with the ramps.
6. Position the machine at the lowest possible posi-
tion on the transport platform, with the center of
gravity of the load over center line of the trans-
port vehicle.
7. Lower the bucket onto the loading area.
8. Stop the engine.
9. Raise the arm rests/safety bars to apply the park-
ing brake and lock out the hydraulic functions.
10. Remove the ignition key.
11. Do not allow anyone to stay in the cab.
12. Close all doors and the engine cover.
13. Tie down the machine as follows:
a. Make sure the authorized maximum height
is not exceeded.
b. Place blocks in front and behind tracks to
prevent movement.
c. Securely strap the machine at the tie-down
points (A, Fig. 12) to the platform. Use only
belts or chains of sufficient capacity.

Fig. 12 - Tie-Down Points

Printed in U.S.A. 39 50950457/A0719

Safety

50950457/A0719 40 Printed in U.S.A.

 Chapter 3
LUBRICATION

Types of Lubricants Lubricant Capacities

IMPORTANT: Use of lubricants not corresponding
to manufacturer recommendations may invalidate
warranty claims. Always dispose of waste lubrica-
tion oils and hydraulic fluids according to environ-
mental laws or take to a recycling center for proper
disposal. DO NOT pour fluids onto the ground or
down a drain.
Listed below are the locations, temperature ranges
and types of recommended lubricants to be used
when servicing this machine. Refer to the separate
engine manual for more information regarding
recommended engine lubricants, quantities required
and grades.

System Type Type and Amount of Lubricant

Use Petro Canada HVI60, Mobil DTE 15M or equivalent, which contain anti-rust, anti-foam, and anti-oxidation
Hydraulic additives, and conforms to ISO VG46.
Capacity: 30.0 L (8 U.S. gallons)
Grease Fittings Use lithium based grease
Refer to the Engine Operator’s Manual for specific engine oil recommendations. Service Classification:
API-CK-4 preferred, API-CJ-4 SM acceptable.
Capacity: 5.87 L (6.2 U.S. quarts)

Engine Oil

Add a mixture of 50% water, 50% ethylene glycol to the recovery tank if coolant level in recovery tank is low.
Anti-Freeze
Entire System Capacity:
Coolant
6.62 L (1.75 U.S. gallons)

Printed in U.S.A. 41 50950457/A0719

Lubrication

Lubrication Points
Wipe dirt from the fittings before and after applying
grease to prevent contamination. Replace any miss-
ing or damaged fittings. Avoid excessive greasing to
minimize dirt build-up.

Fig. 15 - Grease Fittings on Lift Cylinder Rod End

Fig. 13 - Grease Fitting On Hitch Pin

Fig. 16 - Grease Fitting on Lift Cylinder Base End

Fig. 14 - Grease Fitting on Lift Arm Pivot

50950457/A0719 42 Printed in U.S.A.

 Lubrication

Lubrication Schedule/Intervals

250

10
500

50/1000
500
Prefilter
Fig. 17 - Lubricating Service Locations

10 Hours 50 Hours 250 Hours 500 Hours

Lubrication Procedure
(or Daily) (or every week) (or every 6 months) (or Annually)
Check Engine Oil Level X
Check Hydraulic Oil
X
Level
Grease Hitch, Hitch-
related Cylinder Pivots X
and Latch Pins
Grease Lift Arm Pins X X
X
Change Engine Oil X
(Initial Oil Change)
Change Travel Motor
X*
Gear Oil
Change Hydraulic Oil X
Check and Drain Water
X
Separator
Change Coolant X

* Change travel motor gear oil every 2000 hours or with any drive motor repair.

Printed in U.S.A. 43 50950457/A0719

Lubrication

Filter Table

Maximum Interval

Service Procedure
10 Hours 50 Hours 250 Hours 500 Hours
(or Daily) (or every week) (or every 6 months) (or Annually)

Change hydraulic oil X

X
filter (At Initial Oil Change)

Change engine oil filter

X

Change cab air filter, if

X
applicable

Change outer air

cleaner filter element.
Check and change inner X
air cleaner element if
necessary

Replace Filter in Water

X
Separator

Replace Main Fuel Filter X1 X

1. Non-DPF machines require a 250 main fuel filter change interval

50950457/A0719 44 Printed in U.S.A.

 Lubrication
Lubrication and Filter Changes
Table 1 - Lubrication and Filter Changes

Maximum Interval
1000
Service Procedure 50 Hours 150Hours 250Hours 500Hours
10 Hours Hours
(or (or every (or every (or
(or daily) (or every
weekly) 4 months) 6 months) annually)
2 years)
Lubricate grease fittings (See Fig. 36 on page 54) X
Change hydraulic oil return filter X1 X
Travel motor gear oil X2
Change cab air filter, if applicable X3

Lubricate all levers, cables and hinges with oil X

Change outer air cleaner filter element; check and
X3
change inner air cleaner element if necessary
Change engine oil/filter X
Change coolant X
Change hydraulic oil X
Primary fuel filter X4
Water separator fuel filter X

1. After first 50 hours; every 500 hours thereafter.

2. Every 2000 hours.
3. Replace if needed.
4. Non-DPF machines require a 250 hour interval change.

General Information
IMPORTANT: Whenever service is performed on
hydraulic components (valves, cylinders, hoses,
etc.), fuel tanks and lines, care must be taken to
prevent discharging fluid onto the ground. Catch
and dispose of fluid per local waste disposal
NEVER service this unit when any part of the regulations.
machine is in motion. ALWAYS BE SURE to
exercise the “Mandatory Safety Shutdown
Procedure” (see Safety chapter) BEFORE ser-
vicing this equipment.

Routine lubrication is an important factor in pre-

venting excessive part wear and premature failures.
Loader and engine operation depend on using cor-
rect grade, high-quality lubricating oils. This chap-
ter and the chart below list locations, temperature
ranges and types of recommended lubricants to be
used when servicing this machine. In addition, refer
to the engine manual for specific grades and ratings
as specified by the engine manufacturer.

Printed in U.S.A. 45 50950457/A0719

Lubrication
Hydraulic Oil Reservoir
C (whichever occurs first). For details, refer to
B machines.
A
Fig. 18 - Locations of hydraulic oil filter and
engine oil and hydraulic oil filter dipsticks.
The oil reservoir for hydraulic and hydrostatic sys-
tems has a capacity of 8.0 U.S. gallons (30 liters).
A dipstick built into the hydraulic reservoir cap (A,
Fig. 18) provides a visual oil level indicator for con-
venient maintenance of the hydraulic oil level. The
engine oil dipstick (B, Fig. 18) and the hydraulic oil
filter (C, Fig. 18) is also shown.
The hydraulic oil reservoir should be drained and
filled after every 500 hours of operation or annually
(whichever occurs first). The hydraulic oil reservoir
drain plug (D, Fig. 19) is located behind the left rear
track.
Fig. 19 - Location of hydraulic oil reservoir drain
plug.
50950457/A0719
Use XPRT™ or Petro-Canada Premium HVI60
hydraulic oil (or ISO VG46 equivalent) that con-
tains anti-rust, anti-foam and anti-oxidation addi-
tives. Hydraulic oil filter element should be replaced
after every 500 hours of operation or annually
“Hydraulic Oil Filter Element Replacement” proce-
dure in the Hydraulics Work System chapter.
NOTE: An initial 50-hour hydraulic oil filter
element replacement is recommended for new
Hydraulic Oil Tank Drain Procedure
1. Open the engine access cover and lock open the
rear grille.
2. Because the tank is pressurized, slowly remove
the hydraulic oil tank cap from the filler neck.
3. Underneath the left riser, remove the drain plug
on the hydraulic oil tank. Place a suitable con-
tainer under the drain plug hole to catch the
hydraulic oil.
NOTE: Care must be taken to prevent discharg-
ing fluid onto the ground. Catch and dispose of fluid
per the local waste disposal regulations.
46 Printed in U.S.A.

Crankcase Oil
Fig. 20 - Engine Oil Fill Cap Location
The Yanmar three-cylinder diesel engine crank-
case has a capacity of 5.87 L (6.2 U.S. quarts). The
following chart recommended oil viscosity for the
Yanmar engine.
Fig. 21 - Oil Viscosity Chart (Recommended)
Printed in U.S.A.
Lubrication
Engine oil should be changed and filter element
replaced every 500 hours of service. Access to the
engine oil filter and drain plug is from underneath
the machine, through the rear belly pan (F, Fig. 22).
Fig. 22 - Rear Belly Pan Location
The engine oil filter (G, Fig. 23) is located on the
left side of the engine.
Fig. 23 - Engine Oil Filter Location
Refer to the “Oil Filter Removal” and “Oil Filter
Installation” procedures in the Engine chapter of
this manual.
47 50950457/A0719
Lubrication

Grease Fitting Locations

IMPORTANT: Use of lubricants not corresponding to manufacturer recommendations may invalidate war-
ranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws
or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.
Wipe dirt from the fittings before applying grease to prevent contamination. Replace any missing or dam-
aged fittings. To minimize dirt buildup, avoid excessive greasing.

Fig. 24 - Grease Fitting Locations

50950457/A0719 48 Printed in U.S.A.


Engine Cooling System
IMPORTANT: Check the cooling system every
day to prevent overheating, loss of performance or
engine damage.
Checking Coolant Level
1. Park the machine on a level surface.
2. Perform the “Mandatory Safety Shutdown
Procedure” on page 8.
3. Wait until the engine has cooled. See
“Maintenance and Service Safety Practices” on
page 13.
4. Open the engine cover according to “Engine
Access” on page 37.
5. Wait for the machine to cool completely.
Do not remove radiator cap when the coolant is
hot. Serious burns may occur.
H 3. Wait until the engine has cooled. See
Fig. 25 - Coolant Expansion Reservoir
6. Check the coolant level in the expansion reser-
voir (H, Fig. 25). Coolant level must be between
the full (T) and low (S) marks on the expansion
reservoir. Add coolant to the expansion reservoir
as required.
IMPORTANT: The coolant system is specifically
designed for coolant level top-off only through the
expansion reservoir. Do not add top-off coolant
directly to the radiator
Printed in U.S.A.
Lubrication
NOTE: Use a low-silicate ethylene glycol-based
coolant, mixed with quality water and supplemental
coolant additives (SCAs) suitable for heavy-duty
diesel engines. See “Fluids/Lubricants Types and
Capacities” on page 301 and the engine operation
manual for additional information.
Cleaning Radiator Fins
The radiator fins can become blocked during use
which will lead to reduced cooling function and
engine overheating. Clean the radiator cooling fins
after every 250 hours or 6 months of operation,
whichever occurs first.
1. Perform the “Mandatory Safety Shutdown
Procedure” on page 8.
2. Wait until the engine has cooled. See
“Maintenance and Service Safety Practices” on
page 13.
3. Open the engine cover according to “Engine
Access” on page 37.
4. Clean the radiator fins by blowing air/water
through the fins from the rear of the radiator,
toward the engine.
IMPORTANT: Use care. High pressure can dam-
age radiator fins.
Draining/Flushing Cooling System
1. Park the loader on a level surface.
2. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
“Maintenance and Service Safety Practices” on
page 13.
4. Open the engine cover according to “Engine
Access” on page 37.
•
Liquid cooling systems build up pressure as
the engine becomes hot. Before removing the
radiator cap, stop the engine and let the system
cool. Remove the radiator cap only after the
coolant has cooled. Remove the cap slowly or
severe burns may result.
49 50950457/A0719
Lubrication
5. Slowly loosen radiator cap (I, Fig. 26) and allow diesel engines. See “Fluids/Lubricants Types and
pressure to escape. Remove cap. Capacities” on page 301 and the engine operation
manual for additional information.
10. Reinstall the radiator cap and tighten securely.
11. Start and run the engine until it reaches operat-
ing temperature.
12. Check the coolant level according to “Checking
Coolant Level” on page 42.

Fig. 26 - Radiator Cap

6. Position a suitable collection container, with a

minimum capacity of 5.87 L (6.2 U.S. quarts)
underneath the radiator.
IMPORTANT: Dispose waste coolant according to
environmental laws. DO NOT pour coolant onto the
ground or down a drain.
7. Remove the drain plug (J, Fig. 27) and drain the
coolant into the container.

Fig. 27 - Cooling System

8. Replace the radiator drain plug and tighten

securely.
9. Fill the radiator with coolant to the lip of the fill
cap opening. Fill expansion reservoir (K, Fig.
20) with coolant to the low (S) mark.
NOTE: Use a low-silicate ethylene glycol-based
coolant, mixed with quality water and supplemental
coolant additives (SCAs) suitable for heavy-duty

50950457/A0719 50 Printed in U.S.A.

 Chapter 4
MAINTENANCE
Proper care and service improves machine opera-
tional readiness and service life.
Perform maintenance as indicated in the
“Maintenance Schedule” on page 34, or earlier if
required by conditions.
Read and understand the “Safety” Chapter in
this manual, starting on page 7, before servic-
ing the machine. Follow all applicable warnings
and instructions. Check for correct function
after performing maintenance. Failure to follow
instructions can result in injury or death.
BEFORE performing any maintenance, perform
the “Mandatory Safety Shutdown Procedure”
on page 8.
Fluid leaks from hydraulic hoses or pressurized
components can be difficult to see, but pres-
surized oil can have enough force to pierce the
skin and cause serious injury. Always use a
piece of wood or cardboard to check for sus-
pected hydraulic leaks. Never use your hands.
Obtain immediate medical attention if pres-
surized oil pierces the skin. Failure to obtain
prompt medical assistance could result in gan-
grene or other serious damage to tissue.
Do not smoke or allow any open flames in the
area while checking or servicing the hydraulic,
battery and fuel systems because all contain
highly flammable liquids or explosive gases,
which can cause an explosion or fire if ignited.
Wear a face shield when disassembling spring
loaded components or working with battery
acid. Always wear eye protection to protect
eyes from electric arcs from shorts, fluids
under pressure, and flying debris or loose
material. Wear a helmet or goggles with special
lenses when welding or cutting with a torch.
Printed in U.S.A.
When working beneath a raised machine,
always use blocks, jack-stands or other rigid
and stable supports. Wear appropriate pro-
tective clothing, gloves and shoes. Keep feet,
clothing, hands, and hair away from moving
parts.
Always apply the lift arm support when main-
tenance work requires the lift arm in the raised
position See “Lift Arm Support” on page 183.
NEVER weld on the machine without consulting
the manufacturer. Parts may be designed so
that they should not be welded and/or special
metals may be used which require special weld-
ing techniques. NEVER cut or weld on fuel lines
or tanks.
If repair welding is ever required, remove the
positive (+) battery terminal connection before
starting to weld. Be sure to attach the ground
(-) cable from the welder as close as possible to
the area to be repaired.
Allow only trained and authorized personnel,
with full knowledge of safe procedures, to per-
form machine maintenance and service.
If any guards, shields, and covers were
removed during maintenance, BE SURE to
replace them in their original positions BEFORE
starting the machine.
51 50950457/A0719
Maintenance

Do not use the machine when maintenance

is due. Postponed maintenance can result in
a serious reduction of the service life of the
machine, costly equipment failures, and con-
tribute to unsafe operating conditions.

Do not perform maintenance or service not

included in this manual. Maintenance and ser-
vice not included in this manual should only be
performed by a authorized repair shop.

Maintenance Schedule
IMPORTANT: When washing the machine using
water, do not direct the water onto any electrical
connection, electrical component, or electronic
component. Water may cause malfunction or dam-
age. Power washing or other high-pressure jets
Do not postpone scheduled maintenance. may cause physical damage.
Postponing maintenance can reduce the ser-
vice life of the machine, cause more serious NOTE: Accumulated operation time is shown on
and costly equipment failures, and contribute the multi-function display.
to unsafe operating conditions. Maintenance
intervals apply to average operating conditions
and loads. More frequent maintenance may be
required depending upon the level and type of
use.

Checks, Cleaning, and Inspection

Table 2 - Checks, Cleaning, and Inspection

Maximum Interval
Service Procedure 250 Hours
10 Hours 500 Hours
(or every 6
(or Daily) (or Yearly)
months)
Clean machine X
Inspect machine for general wear/damage X
Check bucket cutting edge X
Check safety interlock system X
Inspect tracks for damage/wear X
Check automatic track tensioning X
Check engine oil level and condition X
Check coolant level and condition X
Check hydraulic fluid level and condition X

50950457/A0719 52 Printed in U.S.A.

 Maintenance

Maximum Interval
Service Procedure 250 Hours
10 Hours 500 Hours
(or every 6
(or Daily) (or Yearly)
months)
Check fuel level and fill if necessary X
Check windshield washer system and wiper blade, if
X
applicable
Check exhaust for excessive smoke emission X
Check hydraulic cylinder piston rods for damage/wear; clean
X
if necessary
Check ROPS structure (all fasteners must be installed and
X
tightly secured)
Check water separator and drain water, if present X1
Check coolant system for leaks, dirt and debris X
Check hydraulic hoses and tubes for cracks, leaks and/or
X
debris
Check hydraulic tank, valves and cylinders for leaks and/or
X
damage
Check coolant anti-freeze mixture X
Check belt tension and condition X
Check engine cover lock X
Check engine idle X
Clean radiator/oil cooler fins X
Check hinge pins, joint bushings, pivot bolts and bearings X
Check engine mounts X
Check exhaust system for damage X
Clean battery terminals X
Check timing belt X
Check fuel injectors X
Check electrical system for damage, wire routing X

1. An engine error code displays if water is present in the water separator. Refer to “Yanmar Engine Diagnostic Trouble
Codes (DTC)” on page 88.

Leakage Check
Table 3 - Leakage Checks

Maximum Interval
Service Procedure 250 Hours
10 Hours 500 Hours
(or every 6
(or Daily) (or Yearly)
months)
Check engine for oil/coolant leaks X
Check cooling system for leaks X
Check hydraulic system for leaks X

Printed in U.S.A. 53 50950457/A0719

Maintenance
Functional Check
Table 4 - Functional Check

Maximum Interval
Service Procedure 250 Hours
10 Hours 500 Hours
(or every 6
(or Daily) (or Yearly)
months)
Check seat belt X
Check service and parking brake function X
Check joystick operation X
Check windshield wipers, if applicable X
Check control switches/buttons, indicators and audible warn-
X
ing devices
Check installed lighting systems X

Engine Maintenance

Check Engine Mounting Hardware

All bolts that secure the engine mounting brack-
ets to the engine and the loader frame should be
checked and re-tightened as necessary. A

Allow hot engine and hydraulic system compo-

nents to cool before servicing.

Fig. 28 - Engine Access Cover Latch

Engine Access
3. Pull up on handle (B, Fig. 29) inside the top
1. Perform the “Mandatory Safety Shutdown
left lip of the rear door. Swing the door open to
Procedure” on page 8.
access engine components.
2. Pull up on the latch (A, Fig. 28) and lift the
cover. Fig. 29 - Rear door Latch

NOTE: After opening the rear door, engage the

door stop (C, Fig. 30) near the bottom pivot which
holds the door open.

50950457/A0719 54 Printed in U.S.A.

 Maintenance

C
Engine Access Cover
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Engine Access Cover Removal and

Installation
1. Remove the attachment.

Fig. 30 - Rear door stop engaged

Hose removal or component failure can cause

Closing Engine Covers the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.

To avoid injury, keep fingers clear when closing

engine covers. NOTE: Raising the lift arm allows for clearance of
the engine access cover mounting hardware.
2. Raise and support the lift arm using the lift arm
1. Disconnect the rear door stop (C, Fig. 30), and
support device (D, Fig. 31).
firmly close the rear door.
NOTE: It is important for the rear door to close
D
and latch completely, so the top engine cover
latch aligns properly with the pin on the rear door.
Incomplete latching of the rear door/top cover may
cause latches to stick.
2. With the rear door completely closed and
latched, firmly close the top engine cover until it
is completely closed and latched.

Fig. 31 - Lift Arm Support Device

3. Complete the mandatory safety shutdown

procedure.
4. Open the engine access cover and lock open the
rear grille.

Printed in U.S.A. 55 50950457/A0719

Maintenance
5. Disconnect the gas spring (E, Fig. 32) from the Engine Oil
engine access cover by removing the gas spring
clip at the access cover end of the gas spring,
and then pulling the gas spring off the ball stud Checking Engine Oil Level
on the access cover. Check the engine oil level daily before starting the
machine, or after every ten hours of use.

E IMPORTANT: For new units, the initial oil change

should be after the first 50 hours.

Fig. 32 - Gas spring on engine access cover.

6. Holding up the engine cover, remove the hard-

ware (F, Fig. 33) securing the access cover
to the ROPS/FOPS assembly and remove the
engine cover. Fig. 34 - Oil Dipstick and Fill Cap

1. Park the machine on a level surface.

F
2. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
3. Wait until the engine has cooled. Refer to
“Maintenance and Service Safety Practices” on
page 21.
4. Open the rear door and engine access cover.
5. Pull out the dipstick (A, Fig. 34) and check the
oil level. The oil fill cap (B, Fig. 34) is located
Fig. 33 - Hardware to remove on both sides.
nearby.
6. Wipe the dipstick with a clean cloth and replace
Installation Procedure - Follow all warnings first, it in the engine. Push it in until it is fully
then reverse the removal steps. inserted.
7. Remove the dipstick again. The oil level should
be within the “Add” and “Full” markings.
8. Markings on the dipstick represent full and
low (add oil) levels. Refer to the Maintenance
Interval Chart (page 52) for the service inter-
val for replacing the engine oil and filter.
IMPORTANT: Do not over-fill the engine with oil.
Damage could result.

50950457/A0719 56 Printed in U.S.A.


Changing Engine Oil and Filter
Change the engine oil and filter every 250 hours
thereafter. Refer to “Fuel System Maintenance” on
page 59 for proper grade and type.
IMPORTANT: Oil should be changed more
frequently under heavy work conditions, if higher
sulfur content fuel is used, or if multiple standstill
regenerations are performed.
Reduce the oil change interval if the machine is
exposed to constant ambient temperatures below
-10 °C (14 °F).
1. Park the machine on a level surface.
C Engine Air Filters
Fig. 35 - Rear Belly Pan Opening.
2. Run the engine until it is at operating tempera-
ture. Stop the engine. Remove the rear belly pan
(C, Fig. 35).
3. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
4. Wait until the engine has cooled, but is not
completely cold. Oil will drain faster and more
completely if it is warm.
5. Position a waste oil collection container under
engine oil drain plug to catch draining oil
6. Remove the engine oil drain plug.
IMPORTANT: Dispose waste engine oil according
to environmental laws, or take to a recycling center
for proper disposal. DO NOT pour waste engine oil
onto the ground or down a drain.
Printed in U.S.A.
Maintenance
7. Remove drain plug from the engine oil pan and
allow the oil to drain into the waste oil collec-
tion container.
8. From the engine compartment, remove the oil
filter. Clean the filter sealing surface.
9. Put clean oil on the new oil filter gasket. Install
the filter and tighten 3/4 of a turn past the point
where the gasket contacts the filter head.
10. Reinstall and tighten the drain plug to 55 Nm
(40.5 lbs-ft.).
11. Remove the oil cap and add the recommended
oil. Refer to .”Fuel System Maintenance” on
page 59 .
12. Start the engine and let it run for several minutes
at low idle. Stop the engine. Check for leaks
at the oil filter, drain plug and remote oil drain
hose. Check the oil level. Add oil if it is not at
the top mark on the dipstick.
NOTE: Oil capacity listed is approximate. Always
verify proper oil level with the engine oil dipstick.
IMPORTANT: Do not operate the engine without
the air cleaner components installed or damage to
the engine could occur.
The air cleaner consists of an outer (primary) filter
element and an inner (secondary) filter element. An
air filter restriction indicator for monitoring the con-
dition of the elements is located on the right side of
the front of the air cleaner. If the air filter becomes
restricted, this indicator will turn red to warn the
operator that the element(s) require service. Push
the reset button located on the end of the indicator
after fitting a clean element.
NOTE: Before replacing the filter element(s),
push the reset button on the indicator. Start the
engine and adjust the throttle to full speed. If the
indicator does not turn red, do not replace the
element(s).
The outer element should be replaced only when
the restriction indicator turns red. The inner element
should be replaced every third time the outer ele-
ment is replaced, unless the outer element is dam-
aged or the inner element is dirty.
57 50950457/A0719
Maintenance
Along with a daily check of the restriction indicator, 1. Carefully pull the outer element (G, Fig. 37) out
check the air cleaner intake hose and clamps, and of the housing. Never remove the inner element
the mounting bracket hardware to be sure they are unless it is to be replaced.
properly tightened.
2. Clean out any dirt built up in the housing. Leave
the inner element installed during this step to
2
prevent debris from entering the engine intake
4
manifold.
3
3. Replace the outer element.
1 NOTE: Manitou Group does not recommend
cleaning the outer element.
6 4. Use a trouble light inside the outer element to
inspect for spots, pinholes or ruptures. Replace
the outer element if any damage is noted. The
outer element must be replaced if it is oil- or
5
soot-laden.

Fig. 36 - Dual Element Air Cleaner

1. Restriction Indicator Inner Element
2. Element Housing
3. Elbow Hose
4. Hose Connector
5. Sound Diffuser/Intake Suppressor
6. Air Intake Tube

Access
1. Open the rear door and engine access cover.
2. Unlatch the clamps on the air cleaner and
H
remove the cover. Clean out any dirt built up in
the cover assembly.
Fig. 38 - Inner element shown.
Outer Element
NOTE: Replace the inner element (H, Fig. 38)
only if it is dirty or if the outer element has been
replaced three times.
1. Before removing the inner element from the
housing, clean out any dirt built up in the hous-
ing. Leave the inner element installed during
this step to prevent debris from entering the
engine intake manifold.
2. Remove the inner element.
G
Re-installation
1. Check the inside of the housing for any damage
Fig. 37 - Outer element shown. that may interfere with the elements.

50950457/A0719 58 Printed in U.S.A.


2. Be sure that the element sealing surfaces are
clean.
3. Insert the element(s), making sure that they are
seated properly.
4. Secure the cover to the housing with clamps.
5. Check the hose connections and be sure they are
all clamped and tightened properly.
6. Reset the restriction indicator by pressing the
reset button.
Belt Maintenance
Check belt condition monthly, or after every 100
hours of use. Replace or adjust if necessary.
Checking and Adjusting Belt Tension
1. Perform the “Mandatory Safety Shutdown
Procedure” on page 8.
2. Wait until the engine has cooled. See
“Maintenance and Service Safety Practices” on
page 13.
3. Open the engine cover according to “Engine
Access” on page 37.
4. Inspect belt (I, Fig. 39) for damage. If damaged,
have the belt replaced by an authorized repair
shop.
I
Fig. 39 - V-Belt
5. Press on belt (A) mid-way between pulleys to
check deflection. The belt should not deflect
more than 8 mm (5/16”).
Printed in U.S.A.
Maintenance
6. If deflection is more than 8 mm (5/16”): Loosen
adjustment bolt (C) and rotate alternator (B)
outward until belt tension is correct. Tighten
bolt (C) and re-check belt tension.
DPF Exhaust System Service
DPF soot filter replacement is required when the
DPF Service screen (Fig. 40) is shown on the
multi-purpose display.
Fig. 40 - DPF Service Screen
NOTE: DPF service should be performed only by
an authorized dealer.
Fuel System Maintenance
Diesel fuel is flammable. Keep the machine
away from open flames. Do not smoke when
refueling or when working on the engine. Stop
the engine before fueling.
Wear eye protection. The fuel system is under
pressure and fuel could spray out when remov-
ing any fuel system component.
Wipe up spills immediately. NEVER use a shop
rag to catch draining/leaking fuel. Vapors from
the rag are flammable and explosive.
Failure to follow these instructions can cause
fire and result in injury or death.
59 50950457/A0719
Maintenance
1. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Unlock fuel cap (E, Fig. 41) using the ignition
Use only proper types and grades of diesel fuel.
key and remove the fuel cap from the fuel filler
Refer to “Checking Engine Oil Level” on page
neck.
56.

NOTE: The fuel tank is filled at the factory with

United States off-road grade diesel fuel, which
is dyed red for identification. It may take several
fillings of the fuel tank before the red dye is purged
from the fuel system. E
IMPORTANT: Service the fuel system only
in an absolutely clean environment to avoid
contamination.

Adding Fuel

Fig. 41 - Fuel Filler Cap

3. Inspect the wire-mesh fuel strainer located in the

Static electricity can produce dangerous sparks
filler neck opening and remove any accumulated
at the fuel-filling nozzle. Do not wear polyester,
residue. Replace the strainer if damaged.
or polyester-blend clothing while fueling. Before
fueling, touch the metal surface of the machine 4. Fill the fuel tank by adding fuel through the fuel
away from the fuel fill to dissipate any built-up filler neck opening.
static electricity. Do not re-enter the machine
but stay near the fuel filling point during refuel- IMPORTANT: Refer to “Checking Engine Oil
ing to minimize the buildup of static electricity. Level” on page 56 and the engine operation
Do not use cell phones while fueling. Make sure manual for proper fuels. Use of improper fuels can
the static line is connected from the machine to cause engine damage.
the fuel truck before fueling begins.
5. When the fuel tank is full, replace and lock fuel
cap (E) in the fuel filler neck opening.
Ultra-Low Sulfur Diesel (ULSD) poses a greater
static ignition hazard than earlier diesel formu-
lations. Avoid death or serious injury from fire Water Separator Inspection/Maintenance
or explosion; consult with your fuel or fuel sys-
tem supplier to ensure the entire fuel delivery
system is in compliance with fueling standards
for proper grounding and bonding practices.
NEVER service the fuel system while smoking,
while near an open flame, or after the engine
Though not necessary to leave locked, the use of a has been operated and is hot.
locking fuel cap protects the loader from fuel theft
or fuel system vandalism. The key to this lockable
Inspect the water separator daily, or every day
fuel cap should be secured to the loader’s key ring.
before use. The water separator is located between
A torque override features aids in the proper instal-
the fuel tank and the main fuel filter and is used to
lation of the fuel cap. It produces an audible click as
remove finely dispersed water in diesel fuel. Water
the o-ring that seals the cap is properly compressed.
can be drained from the separator by opening the
To operate the lockable fuel cap:
valve located at the bottom of the separator bowl.

50950457/A0719 60 Printed in U.S.A.

 Maintenance
IMPORTANT: Water in the fuel system can cause
severe engine damage. Drain water from the water
separator anytime water is present.
The water separator contains an indicator ring (F,
Fig. 42) indicating the presence of water in the fuel Do not use the starter motor to crank the engine
to prime the fuel system. Damage to the engine
system
starter motor, coils, pinion/ring gear could
result.
1. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Wait until the engine has cooled. IMPORTANT: Dispose waste fuel according to
environmental laws. DO NOT pour fuel onto the
3. Open the engine cover. ground or down a drain.

Changing Fuel Filter

F NEVER service the fuel system while smoking,

while near an open flame, or after the engine
has been operated and is hot.

Fig. 42 - Water Separator

4. Inspect the water separator for the presence of D

water:
• If the indicator ring (F) is at the bottom of the
cup, no action is required.
• If the indicator ring (F) is floating off the bot-
tom of the cup, water is present and needs to be
drained.
5. Drain water from the water separator:
Fig. 43 - Engine Fuel Filter
• If water needs to be drained, position a suitable
collection container underneath the water sep- The engine has a fuel filter (D, Fig. 43) located on
arator drain. the left side of the engine. To change it:

• Turn the fuel shut-off valve lever (G) on the
water separator to the OFF position.
• Loosen drain plug (H) at the bottom of the water
separator. Allow water to drain until indicator
ring falls to the bottom of the cup.
6. Prime the fuel system by turning the ignition
key to the ON position without starting the
engine for 30 seconds.
Printed in U.S.A.
1. Shut off the fuel supply by turning the fuel shut-
off valve on top of the water trap.
2. Remove the fuel filter element.
3. Lubricate new fuel filter element gasket with
diesel fuel.
61 50950457/A0719
Maintenance
4. Install and tighten the filter element one-half
turn past point the where the gasket contacts the
filter head.
5. Turn shutoff valve on water separator to ON.
6. Prime the fuel system by turning the ignition
key to the ON position without starting the I
engine for 30 seconds.

Do not use the starter motor to crank the engine

to prime the fuel system. Damage to the engine
starter motor, coils, pinion/ring gear could
result.
Hydraulic System Maintenance
Fig. 44 - Hydraulic Oil Dipstick and Fill Neck
When hydraulic fluid is required, allow the system
to cool. Slowly remove the oil fill cap, allowing
the pressure to dispel before removing the cap
completely.
Check the hydraulic oil level daily before starting
the machine, or after every ten hours of use.

1. Park the machine on a level surface. Fully

retract all hydraulic cylinders (lift arm down;
Never use your hands to search for hydraulic
fluid leaks; use a piece of paper or cardboard bucket flat).
to find leaks. Escaping fluid under pressure can 2. Perform the “Mandatory Safety Shutdown
be invisible and can penetrate the skin, causing Procedure” on page 16.
serious injury. If any fluid is injected into your
skin, see a doctor at once. Injected fluid MUST 3. Wait until the engine has cooled.
be surgically removed, or gangrene may result.
4. Open the engine cover and unscrew the dipstick
from the fill neck.
Checking Hydraulic Oil Level
The machine has a dipstick (I, Fig. 44) located
in the engine compartment. Check the fluid level
with the lift arm lowered and the attachment on the
ground.

Fig. 45 - Hydraulic Oil Level FULL Mark on the

Dipstick

50950457/A0719 62 Printed in U.S.A.


5. Check the level of the hydraulic oil on the dip-
stick (J, Fig. 45)
6. Add hydraulic fluid as required. Replace the
cap.
Changing Hydraulic Oil and Filter
NOTE: The hydraulic oil filter can be changed
without changing the hydraulic oil or draining the
hydraulic reservoir.
Change the hydraulic oil filter after the first
50 hours, and after 500 hours or 1 year of use
thereafter.
Change the hydraulic oil if it becomes contami-
nated, after major repairs, and/or after 500 hours or
1 year of use.
1. Perform the”Mandatory Safety Shutdown
Procedure” on page 16.
2. Wait until the engine has cooled. Refer to
““Maintenance and Service Safety Practices” on
page 21.
3. Open the engine cover.
4. Position a waste oil collection container with a
capacity of at least 30 L (8 gals.) underneath the
hydraulic oil reservoir drain plug (K, Fig. 46).
K the engine compartment.
Fig. 46 - Hydraulic Oil Drain Plug
NOTE: The hydraulic reservoir drain plug is
accessed from underneath the machine at the bot-
tom left of the hydraulic oil reservoir.
5. Remove the hydraulic reservoir drain plug and
allow the oil to drain completely.
Printed in U.S.A.
Maintenance
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws or take to a recy-
cling center for proper disposal. DO NOT pour onto
the ground or down a drain.
L
Fig. 47 - Hydraulic Oil Filter
6. Remove the hydraulic oil filter (L, Fig. 47),
using a filter wrench if necessary. Carefully
clean the filter head mounting surface with a
clean cloth.
7. Apply a coating of clean oil on the new oil filter
gasket. Install the filter and tighten 3/4 rotation
past the point where the gasket contacts the filter
head.
8. Re-install and tighten the drain plug.
9. Remove hydraulic dipstick/oil fill cap (I, Fig.
44) and add hydraulic oil until the level reaches
the FULL marking (J, Fig. 45) on the dipstick.
10. Replace and tighten the hydraulic oil fill cap.
Close and lock the hydraulic tank cover. Close
NOTE: Refer to “Fuel System Maintenance” on
page 59 for proper hydraulic oil grade and type.
Hydraulic oil capacity listed is approximate.
11. Start the machine. Cycle through all hydraulic
functions several times to purge air from the
hydraulic system. Shut down the machine.
12. Check the machine for hydraulic oil leaks.
Correct any leaks as required.
13. Add oil to the hydraulic system as required
until the level reaches the FULL marking on the
dipstick. Replace and tighten the hydraulic oil
dipstick/fill cap.
63 50950457/A0719
Maintenance

Hydraulic Hose Maintenance

1 Q/05

Hydraulic hoses and connections must be

inspected by a trained technician before the
first use of the machine, and at least annually
thereafter, for leaks and/or damage.

Leaking and/or damaged pressure hose/lines

must be immediately repaired or replaced by an
authorized service center.

Never use your hands to check for suspected Fig. 48 - Hydraulic Hose Manufacture Date
hydraulic leaks. Always use a piece of wood or
cardboard.

Leaks from hydraulic hoses or pressurized Travel Motor Maintenance

components can be difficult to see, but pres-
surized oil can have enough force to pierce the Travel Motor Front Case Oil
skin and cause serious injury.
Replace the travel motor front case oil every 2000
Obtain immediate medical attention if pres- hours/annually or if it becomes contaminated after
surized oil pierces the skin. Failure to obtain major repairs.
prompt medical assistance could result in gan-
grene or other serious damage to tissue.

Always relieve hydraulic system pressure

before performing any maintenance on the
machine. Do not tighten leaking connections
when the hydraulic system is under pressure.

Never weld or solder damaged or leaking pres-
sure tubes and/or screw connections. Always
replace damaged hydraulic components.
Hydraulic hoses must be replaced every six
years from the date of manufacture, even if they
do not appear damaged. The date of manufac-
ture (month or quarter and year) is indicated on
hydraulic hoses. Refer to Fig. 48.
50950457/A0719
Fig. 49 - Lower Travel Motor Oil Plug
1. Park the machine with one of the travel motor
drain/fill hole plugs (O, Fig. 49) at the bottom.
2. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
3. Position a waste oil collection container with a
1 quart/liter (+ 0.10 quarts/liters) underneath the
drain/fill hole plug and remove the lower plug.
IMPORTANT: Always dispose of hydraulic flu-
ids according to environmental laws or take to a
64 Printed in U.S.A.
 Maintenance
recycling center for proper disposal. DO NOT pour Avoid traveling on freshly paved roads or on hot
onto the ground or down a drain. surfaces (e.g. fires, metal sheets exposed to direct
sunlight, etc.). Hot surfaces can damage the lugs or
4. Remove a second plug near the top.
cause irregular wear.
5. Remove the drain/fill hole plug and allow the oil
to drain completely. Avoid moving earth in area where the tracks may
slip, which can cause excessive lug wear.
6. Reinstall the lower drain/fill hole plug. Tighten
securely.
7. Through the top drain/fill plug, fill the travel Track Replacement
motor front case with the same grade and type Refer to “Track Replacement” on page 156
oil used in the hydraulic system. Each travel
motor requires 345 - 375 ml (0.36 - 0.39 qt.) of
hydraulic oil.
Electrical System
8. Reinstall the upper drain/fill hole plug. Tighten
securely.
9. Test the drive system and check for leaks.
Inspect and check the machine’s electrical
equipment at regular intervals. Defects, such as
loose connections or scorched cables much be
Tracks repaired before using the machine.

Track Maintenance Only use proper, original equipment fuses

with the specified current rating. Turn off the
Inspect the tracks daily for damage and wear.
machine immediately if there are any problems
with the electrical system.
IMPORTANT: To avoid damaging the tracks and
to ensure maximum track life, refer to “Rubber
Work on the machine’s electrical system must
Track Use Cautions and Tips” on page 160.
be done only by a trained technician.
Observe the following conditions to extend track
life:

• Avoid traveling or turning on broken stone, jagged

rock, metal or other material that could damage or
cut the tracks.

• Avoid traveling on riverbeds or areas with soft

rocks that could become stuck in the tracks, which
could cause damage to the tracks or cause the tracks
to slip off.

• Avoid using the machine on the seashore. Sea salt

can corrode the metal cores inside the tracks.

• Immediately wipe any spilled fuel, oil, salt or

chemical solvents off of the tracks, as these sub-
stances can corrode the coupling in the metal cores
in the tracks, causing corrosion and peeling.

Printed in U.S.A. 65 50950457/A0719

Maintenance
Battery
Before servicing the battery or electrical sys-
tem, disconnect the negative cable from the
negative battery terminal, or if the machine is
equipped with a battery disconnect switch, turn
the switch to the “OFF” position.
Explosive gas is produced while a battery is in
use or being charged. Keep flames or sparks
away from the battery area. ALWAYS charge the
battery in a well-ventilated area.
Do not jump-start a frozen battery, or it may
explode. A discharged battery can freeze at 0°C
(32°F).
To prevent short circuits keep metal parts on
your clothing and metal watchbands away from
the positive (+) terminal of the battery.
Never lay a metal object on top of a battery,
because a short circuit can result. Battery acid
is harmful to skin and fabrics. If acid spills, fol-
low these first-aid tips:
• If battery acid spills on any clothing, remove it
immediately.
• If acid contacts skin, rinse the affected area
with running water for 10 to 15 minutes.
• If acid contacts eyes, flood eyes with running
water for 10 to 15 minutes. See a doctor at
once. Never use any medication or eye drops
unless prescribed by the doctor.
• To neutralize acid spilled on the floor, use one
of the following mixtures:
• 0.5 kg (1 lbs.) of baking soda in 4 L (4
qts.) of water.
• 0.5 L (0.5 qts.) of household ammonia
in 4 L (4 qts.) of water.
50950457/A0719
The battery on the loader is a 12-volt, wet-cell
battery. To access the battery, open the rear door and
lift the engine cover.
The battery top must be kept clean. Clean it with
an alkaline solution (ammonia or baking soda and
water). After foaming has stopped, flush the bat-
tery top with clean water. If the terminals and cable
connection clamps are corroded or have a build-up,
disconnect the cables and clean the terminals and
clamps with the same alkaline solution.
Using a Booster Battery (Jump-Starting)
Jump-start the machine according to “Using a
Booster Battery (Jump-Starting)” on page 66.
Fuses and Relays
IMPORTANT: Blown fuses indicate electrical sys-
tem malfunctions. Determine what caused the fuse
to blow and repair the problem before replacing the
fuse.
Fuse/Relay Boxes
The fuse/relay panels (Fig. 50, Q , Fig. 51) are
located in the engine compartment near the chassis
right riser and behind a panel in the ROPS/FOPS
(Fig. 52 S, Fig. 53) at the operator’s right elbow
area. The plastic covers are either etched or have a
decal with the type of fuses and relays that can be
found under that particular fuse/relay cover.
Fuse Box #1 Fuse Box #2
Fig. 50 - Engine Fuse boxes shown.
Ref No. Description Function
70 Fuse/60 A Glow Relay
66 Printed in U.S.A.
 Maintenance

Ref No. Description Function

71 Fuse15 A Key Power
72 Fuse/10 A Tail Light
73 Relay/20 A Tail Light
74 Fise60 A Chassis Power
75 Relay/SPST Chassis Power
76 Relay/20 A Rear Light
77 Fuse10 A Rear Light
78 Fuse/20 A EGR
79 Fuse/20 A ECU Power
80 Fuse/60 A Starter/Relay
81 Fuse/5 A Fuel Pump
82 Fuse/10 A Horn Fig. 52 - ROPS/FOPS Fuse panel functions.
83 Relay/SPDT Regen Interlock
Ref No. Description Function
84 Fuse/60 A ROPS Power
1 Relay/20 A Safety Start
85 Relay/SPST ROPS Power
2 Relay/20 A Crank Signal
86 Relay/20 A Hyd Lock
3 Relay/20 A Headlight
87 Fuse/15 A Rear Aux
4 Fuse/10 A Interlock
88 Fuse/15 A Hyd Lock
5 Fuse/3 A Dome Light
6 Fuse/ 20 A 12 V ACC
7 Fuse/5 A Park Switch
8 Fuse/15 A ROPS ACC
9 Fuse/10 A Headlights
10 Fuse/5 A Controls
11 Fuse/3 A LCD Display

Fig. 51 - Fuse Panels in the Engine Compartment S

Fig. 53 - Fuse Panel in the ROPS/FOPS

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Maintenance
Windshield Washer Reservoir
R Before Storage
Fig. 54 - Windshield Washer Reservoir Fill
The windshield washer reservoir (R, Fig. 54) is
located inside the engine compartment. Check the
windshield washer reservoir level daily before start-
ing the machine and fill if necessary.
IMPORTANT: Fill the windshield washer fluid
reservoir with clean tap water or windshield washer
fluid only. If using tap water, add a cleaning agent if
required and/or antifreeze in cold weather.
50950457/A0719
Long-Term Storage
If storing the machine for a long period (longer than
2 months), perform the procedures in this section.
1. Wash the entire machine. Treat vinyl surfaces
in the operator’s compartment with a vinyl
protect-ant.
2. Perform all steps for long-term engine storage
according to the engine operation manual.
3. Lubricate all grease fittings. See “Grease Fitting
Locations” on page 48.
4. Check all fluid levels and top-off as necessary.
5. Add a fuel stabilizer to the fuel system accord-
ing to the fuel supplier’s recommendations.
6. Remove and fully charge the battery. Store the
battery in a cool, dry location.
7. If the machine will not be operated for a month
or longer, apply grease to all exposed hydraulic
cylinder rod areas or retract all cylinders so rod
exposure is minimized. Apply grease to any
remaining rod areas.
8. Protect against extreme weather conditions such
as moisture, sunlight and temperature. Fill the
engine coolant system with the proper mix of
antifreeze and water as required for expected
temperatures according to “Coolant Compound
Table” on page 305.
IMPORTANT: Contact Manitou Group service
for additional storage preparation information if the
machine will be stored in an environment where
temperatures could range below -42°C (-44°F),
and/ or above 49°C (120°F).
After Storage
1. Replace and re-connect the battery.
2. Perform all steps for returning the engine to
service according to long-term engine storage
section in the engine operation manual.
3. Check belt tension.
4. Check all fluid levels and top-off as necessary.
68 Printed in U.S.A.
 Maintenance
5. Start the engine. If any indicators show mal- 7. Switch off all electrical switches.
functions, stop the engine and repair the
8. Unfasten the seat belt, remove the ignition key
machine as required.
and take it with you.
6. If all indicators are functioning properly and
9. Ensure the machine cannot be operated after
reading normally, move the machine outside.
shutdown until further disposal.
7. When outside, park the machine and let the
10. Ensure no environmentally hazardous materi-
engine idle for at least 5 minutes.
als, fluids and/or fuel can escape the machine.
8. Shut down the machine according to Specifically check for leaks from the engine, the
“Mandatory Safety Shutdown Procedure” on hydraulic system and the coolant system.
page 8. Make a visual inspection of the machine
11. Ensure the machine poses no dangers in the
looking for evidence of leaks. place where it is standing.
12. Remove any dirt and/or debris from the engine
compartment, the chassis and the cylinder rod
Final Shutdown / surfaces.
Decommissioning
13. Remove the battery.
IMPORTANT: Dispose of all materials properly.
Used oils/fluids are environmental contaminants 14. Lock the cab door, the storage compartment,
and may only be disposed of at approved collec- the battery and hydraulic filler compartments
tion facilities. Never drain any oils/fluids onto the and the engine compartment. Remove the key(s)
ground, dispose of in municipal waste collection and take it/them with you.
containers, or in metropolitan sewer systems or
landfills. Check state and local regulations for other
material disposal requirements.
If the machine will no longer be used as intended,
shutdown, decommission and dispose of it accord-
ing to the valid regulations.

Before Disposal
1. Shutdown the machine according to valid regu-
lations regarding proper shutdown.
2. Park the machine on level, dry ground. Ensure
the surface can support the weight of the
machine. Ensure the location is protected
against access by unauthorized persons.
3. Move the throttle to the low-idle position and
allow the engine to cool for approximately 2
minutes.
4. Shut off the engine.
5. Move the lift/tilt control(s) to verify that the
controls do not cause movement of the lift arm
or hitch.
6. Raise the arm rests/safety bars to apply the park-
ing brake and lock out the hydraulic controls.
Printed in U.S.A. 69 50950457/A0719
Maintenance

50950457/A0719 70 Printed in U.S.A.

 Chapter 5
ENGINE

General Information Engine Maintenance

Models RT105 and 1050RT are equipped with 3 Refer to “Engine Maintenance” on page 54 for
cylinder, 3-stroke diesel, naturally aspirated Yanmar information about periodic engine maintenance
engines: procedures and information.

• Tier 4 Engine: Model 3TNV88C-KMSV, EPA

Tier 4 final / EU level V emissions compliant.
Engine Components
• Interim Tier 4 Engine: Model 3TNV88-BKMS,
EPA interim Tier 4 emissions compliant.
For detailed information about Yanmar engines, 2

refer the engine operator’s manual, or the engine

service manuals “Yanmar TNV Engine Workshop 12 6

Manual” [Manitou part # 917172] and “Yanmar

TNV Engine Electronic Control Troubleshooting 3

Manual” [Manitou part # 50950006].

9
7

Yanmar Smartassist Connection

Connector (A, Fig. 55) is provided behind the oper- 11

ator’s seat for connecting the Yanmar Smartassist 1

4

tool.
10

Fig. 56 - DPF Model Engine Components

A

Ref. No. DPF Engine Descriptions

1 Air Cleaner
2 Exhaust Tube
3 Radiator/Cooler
4 Coolant Recovery Tank
5 Hydraulic Oil Filter
6 Engine Oil Dipstick
7 Engine Oil Fill Cap
Fig. 55 - Yanmar Smartassist Connector 8 Engine Oil Filter
9 Fuel Filter
10 Fuel Pump
Engine Access 11 Water Trap
12 DPF Cannister
Refer to “Engine Access” on page 54 for infor-
mation about opening/closing the engine access
cover/door.
Printed in U.S.A. 71 50950457/A0719
Engine

1 5

7
6

9 3

4
10
11
8

Fig. 57 - Non-DPF Model Engine Components

Ref. No. Non-DPF Engine Descriptions

1 Air Cleaner
2 Muffler
3 Radiator/Cooler
4 Coolant Recovery Tank
5 Hydraulic Oil Filter
6 Engine Oil Dipstick
7 Engine Oil Fill Cap
8 Engine Oil Filter
9 Fuel Filter
10 Fuel Pump
11 Water Trap

50950457/A0719 72 Printed in U.S.A.

 Engine
Engine Front - DPF Models

3 LN 1/2 CBZY 18 Engine Mount 40 Bracket/Dip Stick

5 CS FL LOCK 3/8x3/4 C5ZY 21 Assy/Dipstick 41 CS FL LOCK 3/8x1/2 C2ZY
6 CS FL LOCK 5/16x3/4 C5ZY 30 ENG/026KW/YAN/3TNV88C-KMSV/ST5 50 Heater/Block (227-2148) Phillips
7 Clamp/Hose .75 x .41 Hole 31 CS 1/2x2-1/2 C5ZY 51 Cord/Block Heater
11 Weldment Engine Mount Bracket 34 CS M10-1.5X25 C10.9 ZY DIN933 52 Tie/Cable .19 x 7.50 Black
14 LN FL SERR 5/16 CZY 37 FW 1/2 AWZY
17 FW 17/32 ZY 39 LW M10 ZY DIN127

Fig. 58 - DPF Engine Front Components

Printed in U.S.A. 73 50950457/A0719

Engine
Engine Rear - DPF Models

2 LN CTR 3/8 CBZY 15 Flexible Drive Plate 34 CS M10-1.5X25 C10.9 ZY DIN933

4 LN CTR 5/8 CBZY 16 Washer (Plated) 35 CS M10-1.5X30 C10.9 ZY DIN933
8 ISOLATOR -11 RED-WHITE 20 Plate/Engine Support 36 CS M8-1.25x12 C8.8 ZY DIN933
9 Plate, Pump Mount 32 CS 5/8x4 C5ZY 38 FW 5/8 AWZY
13 Brace/Engine Top 33 CB 3/8x1 C5ZY 39 LW M10 ZY DIN127

Fig. 59 - DPF Engine Rear Components

50950457/A0719 74 Printed in U.S.A.

 Engine
Engine Front - Non-DPF Models

7 LN 1/2 CBZY 39 CS 1/2x2-1/2 C5ZY 60 Heater/Block (227-2148) Phillips

9 CS FL LOCK 3/8x3/4 C5ZY 45 CS M10-1.5X25 C10.9 ZY DIN933 61 Cord/Block Heater
20 Weldment Engine Mount Bracket 46 CS M10-1.5X30 C10.9 ZY DIN933 62 Tie/Cable .19 x 7.50 Black
32 Washer 49 FW 1/2 AWZY 70 Eng/026KW/YAN/3TNV88-BKMSR/
35 Engine Mount 52 LW M10 ZY DIN127 IT4XPT

Fig. 60 - Non-DPF Engine Front Components

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Engine
Engine Rear - Non-DPF Models

1 Bushing, Oilite Flanged 23 Weldment/Engine Mount 41 HN 1/4 F2ZY

2 Ball/Joint Assy 24 Pivot/Throttle Hand 42 CS 5/8x4 C5ZY
3 Clamp/Hose .50 x .41 Hole 25 Pivot/Throttle Foot 43 CB 3/8x1 C5ZY
6 LN CTR 3/8 CBZY 27 Yoke 45 CS M10-1.5X25 C10.9 ZY DIN933
8 LN CTR 5/8 CBZY 28 LN FL CTR 3/8 CFZY 46 CS M10-1.5X30 C10.9 ZY DIN933
11 Cable, Throttle 29 Pin, Clevis 1/4 X 3/4 47 CS M8-1.25x12 C8.8 ZY DIN933
14 ISOLATOR -11 RED-WHITE 30 Pin, Clip, Rue #8 48 CS M6-1.00X40 C8.8 ZY DI
15 Screw/Shoulder 3/8x1/2 31 Flexible Drive Plate 50 FW 5/8 AWZY
16 Plate, Pump Mount 33 Washer (Plated) 51 HN M6-1 C8 ZY DIN934
18 Bracket/Throttle Suppport 34 FW 17/32 ZY 52 LW M10 ZY DIN127
21 Rod Throttle 36 Bushing
22 Brace/Engine Top 40 CS 3/8x2 C5ZY

Fig. 61 - Non-DPF Engine Rear Components

50950457/A0719 76 Printed in U.S.A.

 Engine
Fuel Circuit - DPF Models

1 Clamp/Hose #04M 23 Nylon Sleeve HG10 x 38” 29 Nylon Sleeve HG10 x 23”
7 Clamp/Hose .75 x .41 Hole 24 Nylon Sleeve HG10 x 29” 41 CS FL LOCK 3/8x1/2 C2ZY
10 Hose/Fuel 5/16 X 25” 25 Hose/Fuel 5/16 x 6’” 50 Fuel Filter Assembly
12 Hose-Fuel 5/16 x 15” 26 Nylon Sleeve HG10 x 4.00” 51 Water Separator
19 Hose/Fuel -05 x 31in 27 Nylon Sleeve HG10 x 18” 52 Pump Assy Fuel Feed
22 Hose/Fuel 5/16 x 40” 28 Hose/Fuel -06 x 20”

Fig. 62 - DPF Fuel Circuit Components

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Engine
Fuel Circuit - Non-DPF Models

4 Clamp/Hose #04M 19 Hose/Fuel 5/16 x 17.5” 70 Filter/Fuel Oil

5 LN 1/4 CBZY 26 Valve/Fuel Shut Off 71 Separator Assy
10 FW 11/32 37 Hose/Fuel 5/16” X 12” 72 Pump Assy Fuel Feed
13 ST HB05-MP04 Brass 38 CB 1/4x7/8 C5ZY
17 Hose/Fuel 5/16 X 25” 44 CS 5/16x3 C5ZY

Fig. 63 - Non-DPF Fuel Circuit Components

50950457/A0719 78 Printed in U.S.A.

 Engine
Air Intake and Exhaust - DPF Models

1 CLAMP/HOSE #52 8 Indicator 15 LW M8 ZY DIN127

2 Clamp/Hose #40 9 Hose/Intake 16 GASKET, MUFFLER
3 Tube-Hose Connector 10 200 Series Elbow 17 Housing/Bottom
4 Clamp/Filter 11 Tube/Exhaust 18 AIR FILTER - OUTER
5 Sound Diffuser 12 Cleaner/Air 19 AIR FILTER - INNER
6 LN FL SERR 5/16 CZY 13 CB 5/16x1 C5ZY
7 FITTING/DIRT INDICATOR 14 HN M8-1.25 C8 ZY DIN934

Fig. 64 - DPF Air Intake and Exhaust Components

Printed in U.S.A. 79 50950457/A0719

Engine
Air Intake and Exhaust - Non-DPF Models

1 CS FL LOCK 3/8x1 C5ZY 8 Hose/Molder Air Filter 15 LW M8 ZY DIN127

2 CLAMP/HOSE #52 9 Sound Diffuser 16 Muffler/Wrapped
3 Clamp/Hose #40 10 LN FL SERR 5/16 CZY 20 Housing/Bottom
4 Tube-Hose Connector 11 Indicator 21 AIR FILTER - OUTER
5 Weldment Muffler Mount 12 Cleaner/Air 22 AIR FILTER - INNER
6 200 Series Elbow 13 CB 5/16x1 C5ZY 30 Gasket/Silencer
7 Clamp/Filter 14 HN M8-1.25 C8 ZY DIN934

Fig. 65 - Non-DPF Air Instake and Exhaust Components

50950457/A0719 80 Printed in U.S.A.

 Engine
Radiator / Cooler Group - DPF Models

1 Clamp/Hose #20 14 Cooler/Hoc/Radiator 27 Hose/Lower Radiator

2 Clamp/Hose 1.12 x .41 Hole 15 Hose/10m3k x 47 28 Weldment/Fan Shroud
3 Clamp/Hose #04M 16 Weldment/Rad Support 29 Fan Shroud Guard
4 Tee MJ10-MJ10-MJ10 17 LN FL CTR 5/16 CFZY 30 Bracket/Dip Stick
5 90 MJ10-MAORB10 18 Cooler Mounting Plate 31 Hose/Hyd -10 x 19in
6 LN LG FL SERR 3/8 CZ 19 Support/Shroud Lh 32 Hose/Hyd -10 x 38in
7 CS FL LOCK 3/8x3/4 C5ZY 20 Support/Shroud Rh 33 Brkt/Hose Shield
8 LN FL SERR 3/8 CZY 21 Brace/Cooler 34 Pad/Rub
9 Clamp/Hose .62 x .41 Hole 22 Cooler Mounting Plate 35 CB 5/16x3/4 C5ZY
10 Seal-Shroud 23 Fan/1HR/16.75” DIA 36 CB 3/8x1 C5ZY
11 Clamp/Hose .75 x .41 Hole 24 CS FL LOCK 3/8x1/2 C2ZY 37 HWHTRS Tap/R 5/16x3/4 CZY
12 Relief Valve 25 Washer 38 CS FL M6-1.00x25 8.8 ZY
13 Hose/Fuel 5/16 x 36.5” 26 Hose/Upper Radiator 39 Bottle/Overflow Assy

Fig. 66 - DPF Radiator / Cooler Group Components

Printed in U.S.A. 81 50950457/A0719

Engine
Radiator / Cooler Group - Non-DPF Models

1 Clamp/Hose #20 13 Hose/Fuel 5/16 x 36.5” 25 Washer

2 Clamp/Hose 1.12 x .41 Hole 14 Cooler/Hoc/Radiator 26 Hose/Hyd -10 x 19in
3 Clamp/Hose #04M 15 Hose / Upper Radiator 27 Hose/Hyd -10 x 38in
4 Tee MJ10-MJ10-MJ10 16 Hose/10m3k x 47 28 Hose/Radiator/Lower
5 90 MJ10-MAORB10 17 Weldment/Rad Support 29 Support/Shroud LH
6 LN LG FL SERR 3/8 CZ 18 Weldment/Fan Shroud 30 Support/Shroud RH
7 CS FL LOCK 3/8x3/4 C5ZY 19 Fan/1HR 14.69” Dia 31 CB 5/16x3/4 C5ZY
8 LN FL SERR 3/8 CZY 20 LN FL CTR 5/16 CFZY 32 CB 3/8x1 C5ZY
9 Clamp/Hose .62 x .41 Hole 21 Cooler Mounting Plate 33 HWHTRS Tap/R 5/16x3/4 CZY
10 Seal-Shroud 22 Brace/Cooler 50 Bottle/Overflow Assy
11 Clamp/Hose .75 x .41 Hole 23 Cooler Mounting Plate
12 Relief Valve 24 CS FL LOCK 3/8x1/2 C2ZY

Fig. 67 - Non-DPF Radiator / Cooler Group Components

50950457/A0719 82 Printed in U.S.A.

 Engine

Adjustments
C
Fan Belt Adjustment

BEFORE beginning this service procedure, per-

form the following SAFETY procedure: C

• Shut off the engine and allow to cool.

(For detailed instructions, refer to the Safety

chapter of this manual.) Fig. 69 - Adjustments Bolts on alternator

4. Rotate the alternator in a clockwise direction

1. Open the engine access cover and lock open the (viewed from the engine end) until the correct
rear door. belt tension is achieved.
5. Re-tighten the bolts.
2. Test the fan belt tension by pushing on the belt
(B, Fig. 68) midway between the alternator and
the engine crankshaft pulley. The belt should Fan Shroud Adjustment
deflect about ½” (13 mm) under a load of 20 lbs.
(90 N). If adjustment is needed, follow the next
steps.
BEFORE beginning this service procedure, per-
form the following SAFETY procedure:

• Shut off the engine and allow to cool.

B
(For detailed instructions, refer to the Safety
chapter of this manual.)

1. Loosen, but do not remove, the two locking

capscrews (D, Fig. 70)on the shroud support
connected to the shroud.

Fig. 68 - Fan Belt Tension test area

3. Loosen the two bolts (C, Fig. 69) on the alterna-

tor, one at the low pivot area and one on top in
the slide bracket.
D

Fig. 70 - Shroud support capscrews

Printed in U.S.A. 83 50950457/A0719

Engine
2. Move the shroud and radiator/oil cooler assem-
bly up or down until the fan is centered in the
shroud opening.
Fig. 71 - Fan centered in the fan shroud
3. Tighten the locking capscrews on the fan shroud
supports to secure the height adjustment.
Engine Removal/Installation
NOTE: Some loss of hydraulic fluid and engine
coolant will occur when disconnecting hydraulic
and coolant hoses. Use absorbent mats to catch
any dripping fluid when disconnecting hoses. Cap
and plug all coolant and hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluid
and engine coolant according to environmental
laws, or take them to a recycling center for proper
disposal. DO NOT pour them onto the ground or
down a drain.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
Engine Removal
IMPORTANT: Park the machine where the engine
can be supported and removed with an engine
hoist or similar device.
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Label all hoses and note their locations before dis-
connecting to ensure correct installation.
As parts are removed during engine removal, store
them in an orderly fashion in a safe, clean place.
50950457/A0719
Cap and plug all exposed coolant/hydraulic system
openings to prevent contamination.
Use proper lifting equipment. Lifting the engine
without proper equipment could result in seri-
ous personal injury or equipment damage. Keep
clear of suspended load.
Diesel fuel is flammable. Keep the machine
away from open flames. Do not smoke when
refueling or when working on the engine. Stop
the engine before fueling.
Wear eye protection. The fuel system is under
pressure and fuel could spray out when remov-
ing any fuel system component.
Collect draining fuel into an approved container
and wipe up spills immediately. NEVER use a
shop rag to catch draining/leaking fuel. Vapors
from the rag are flammable and explosive.
Failure to follow these instructions can cause
fire and result in injury or death.
1. Complete the Mandatory Safety Shutdown
Procedure. See “Mandatory Safety Shutdown
Procedure” on page 16.
2. Open the engine access cover and lock open the
rear door.
3. First, disconnect and remove the negative (-)
battery cable (B, Fig. 72) and then disconnect
the positive (+) battery cable (C, Fig. 72) from
the battery.
C
B
Fig. 72 - Battery cables.
84 Printed in U.S.A.

4. Open the petcock (A Fig. 73) and drain the
engine cooling system.
Fig. 73 - Radiator Petcock
5. Loosen hose clamp and disconnect the coolant
overflow hose (B, Fig. 74) and two P-clips (C,
Fig. 74) and move coolant overflow hose aside.
Cap/plug openings to prevent contamination.
C D
B C
Fig. 74 - Coolant Overflow Hose
Printed in U.S.A.
Engine
6. Unbolt the remote engine oil filter bracket (Z,
Fig. 75) from the left riser.
Fig. 75 - Remote engine oil filter bracket
7. Apply a vacuum or drain the hydraulic system.
Refer to “Changing Hydraulic Oil and Filter” on
page 50.
8. Disconnect the upper and lower hydraulic oil
cooler hoses (D,E, Fig. 76). Cap/plug openings
to prevent contamination.
E
D E
Fig. 76 - Cooling Package
NOTE: BE SURE to use two wrenches on the
hydraulic oil lines, one on the oil cooler fitting and
the other on the hydraulic oil line to prevent dam-
age to the oil cooler.
9. Using a suitable hoist of adequate capacity and
a positive locking mechanism able to support
the radiator/oil cooler or equivalent, remove the
radiator/oil cooler from the machine.
85 50950457/A0719
Engine
NOTE: The cooler weighs approximately 68 kg 13. Remove the four lower fan shroud capscrews
(150 lbs.). (I, Fig. 79) from the lower machine frame and
IMPORTANT: Note the orientation/location of
remove the fan shroud from the machine.
cooler mounting hardware for reassembly.
10. Remove the six capscrews (F, Fig. 77) that
secure the cooling package to the fan shroud.

G Fig. 79 - Fan Shroud Mount

NOTE: Removal of the air cleaner cover and air

filters is necessary for ease of air cleaner housing
removal.
Fig. 77 - Cooling Package
14. Remove the air cleaner cover (J, Fig. 80) to
11. Remove the cooling package (G, Fig. 77) from
access the air filters.
the machine.
12. Remove the two capscrews (H, Fig. 78) that
secure the fuel line and oil dipstick mounting
bracket to the fan shroud. J

H
Fig. 80 - Air Filter Housing

Fig. 78 - Oil Dipstick Mounting Bracket

50950457/A0719 86 Printed in U.S.A.


15. Remove the primary air filter (K, Fig. 81) and
secondary air filter (located behind primary air
filter) and set them a in safe clean location to
avoid contamination.
Fig. 81 - Primary Air Filter
16. Loosen the hose clamp (L, Fig. 82) that secures
the air intake tube to the intake manifold.
L
Fig. 82 - Intake Air Hose
Printed in U.S.A.
Engine
17. Remove two mounting capscrews (M, Fig. 83)
from the left side of the air filter housing and
remove the air filter housing from the machine.
Cap/plug openings to prevent contamination.
Fig. 83 - Air Filter Housing
18. Tag and disconnect the three electrical connec-
tors (N, Fig. 84) from the diesel particulate filter
(DPF).
N
Fig. 84 - DPF Sensor Connectors
87 50950457/A0719
Engine
19. Remove the two capscrews from the DPF front 21. Remove the four capscrews (Q, Fig. 87) that
mounting bracket (O, Fig. 85) to the fuel tank. secure the DPF rear access cover to the fuel
tank.

O
O

Fig. 85 - DPF Front Mount

Fig. 87 - DPF Rear Access Cover

22. Remove the two capscrews (R, Fig. 88) that

secure the DPF to the rear DPF mounting
Always raise the ROPS/FOPS completely, allow- bracket.
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

20. Tilt back the ROPS/FOPS until lock (P, Fig. 86) R
engages.

Fig. 88 - Rear DPF Mounting Bracket

Fig. 86 - ROPS/FOPS Safety Latch

50950457/A0719 88 Printed in U.S.A.


23. Remove the four capscrews (S, Fig. 89) that
secure the DPF to the exhaust manifold and
remove the DPF from the machine. Cap/plug
openings to prevent contamination.
Engine
26. Disconnect the fuel return hose (W, Fig. 91)
from the fuel filter manifold. Cap/plug openings
to prevent contamination.

Fig. 91 - Fuel Filter Manifold

Fig. 89 - DPF to Exhaust Manifold
27. Disconnect the fuel supply hose (X, Fig.
NOTE: It is not necessary to remove the hydraulic 92) from the fuel filter/water separator fil-
oil filter from the hydraulic oil filter manifold. ter manifold. Cap/plug openings to prevent
24. Remove the two hydraulic lines (T, Fig. 90) contamination.
from the hydraulic oil filter manifold. Cap/plug
openings to prevent contamination.
X
25. Remove the four capscrews (U, Fig. 90) that
secure the hydraulic oil filter manifold (V, Fig.
90) to the fuel tank and remove the hydraulic oil
filter assembly.

T
V
T
Fig. 92 - Fuel Supply Hose

Fig. 90 - Hydraulic Oil Filter Assembly

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Engine

28. Disconnect the fuel pump electrical connectors 30. Attach a proper support device (B, Fig. 95) to
(Y, Fig. 93) from the fuel tank. support the fuel tank.

Fig. 93 - Fuel Pump Electrical Connectors Fig. 95 - Fuel Tank Support Device

29. Remove the two capscrews (Z, Fig. 94) that 31. Remove the five capscrews (C, Fig. 96) that
secure the power relay bracket (A, Fig. 94) to secure the fuel tank to the machine frame.
the fuel tank. Remove the fuel tank from the machine.

Fig. 94 - Power Relay Bracket Fig. 96 - Fuel Tank

50950457/A0719 90 Printed in U.S.A.

 Engine

32. Tag and disconnect the three fuel filter hoses (D, 34. Tag and disconnect the two electrical connectors
Fig. 97). (F, Fig. 99) from the fuel filter/water separator.

D
D
D

Fig. 97 - Fuel Filter Hoses Fig. 99 - Fuel Filter/Water Separator Electrical

33. Remove the two capscrews (E, Fig. 98) that
secure the fuel filter bracket to the machine.
Remove the fuel filter and bracket from the
machine.
Connectors
35. Remove the two nuts (G, Fig. 100) that secure
the fuel filter/water separator bracket to the
machine. Remove the fuel filter/water separator
and bracket from machine.

Fig. 98 - Fuel Filter Bracket

Fig. 100 - Fuel Filter/Water Separator Bracket

36. Disconnect the two engine control unit (ECU)

electrical connectors (H, Fig. 101) from the
ECU.

Printed in U.S.A. 91 50950457/A0719

Engine

37. Remove the capscrew (I, Fig. 101) that secures 39. Disconnect and tag the four main engine harness
the ECU ground wire to the machine. electrical connectors (K, Fig. 103).

K
H

Fig. 101 - Engine Control Unit Electrical Connectors
38. Remove the four capscrews (J, Fig. 102) that
secure the ECU to the machine. Remove the
ECU from the machine.
Fig. 103 - Main Engine Harness Electrical
Connectors
40. Remove the braided engine ground wire (M,
Fig. 104) from the grounding lug (L, Fig. 104)
on the frame.

M
Fig. 102 - Engine Control Unit Mount
Fig. 104 - Engine Ground

41. Disconnect the starter motor’s positive cable (N,

Fig. 105) and set it aside.

50950457/A0719 92 Printed in U.S.A.

 Engine
45. Remove the two capscrews (S, Fig. 107) from
42. Disconnect the starter motor’s ground electrical the bottom of the hydrostatic pump support
connector (O, Fig. 105). mount (not shown).

O S

Fig. 105 - Starter Electrical Connectors Fig. 107 - Hydrostatic Pump Mounts

43. Remove the seven capscrews (P, Fig. 106) that NOTE: The engine weighs approximately 317 kg
secure the engine support plate (Q, Fig. 106) to (700 lb.).
the engine and remove the support plate.
46. Attach an appropriate lifting device (T, Fig. 108)
to the engine.
P
Q

Fig. 106 - Engine Support Plate

NOTE: Use an appropriate supporting device to Fig. 108 - Engine Lifting Device
support the weight of the hydrostatic pump when
the engine is removed.
44. Remove the two capscrews (R, Fig. 107) that
secure the hydrostatic pump to the rear of the
engine.

Printed in U.S.A. 93 50950457/A0719

Engine
47. Remove the three capscrews, washers, and
nuts (U, Fig. 109) that secure the front and rear
motor mounts to the frame.
U nections to avoid pinching, chafing, and damage
Fig. 109 - Engine Mounts
48. Using a suitable hoist of adequate capacity and a
positive locking mechanism able to support the
engine or equivalent, remove the engine from
the machine, with the aid of an assistant.
50950457/A0719
Engine Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures will be similar.
IMPORTANT: Always verify electrical connec-
tions are sound and strain is relieved when static
to accommodate moving components and machine
operation. Route, tie, and clamp all wires and con-
consistent with factory design and practice.
Do NOT use any lifting attachments (slings,
chains) that are damaged or of inadequate rated
capacity.
1. Before installing engine, inspect the hydrostatic
pump coupler (A, Fig. 171) and drive plate (B)
in for wear or damage.
2. If there is excessive wear or damage, replace
the worn parts. See “Hydrostatic Pump Drive
Coupling Removal and Installation” on page
145.
3. Inspect the engine mount rubber bushings for
any wear or damage. Replace if required. Also,
inspect the hardware and replace if needed.
4. Using a suitable hoist of adequate capacity and a
positive locking mechanism able to support the
engine or equivalent, remove the engine from
the machine.
NOTE: The engine weighs approximately 317 kg
(700 lb.).
Keep hands and feet clear when positioning the
engine in the machine. Severe pinching/crush-
ing injury can occur.
5. With the aid of an assistant, carefully raise the
engine and move it into position in the engine
compartment.
6. Align the engine mounts on the engine and the
chassis. Also align the hydrostatic pump with
94 Printed in U.S.A.

the coupler inside the flywheel housing (D, Fig.
173).
7. Install the three capscrews, washers, and nuts,
(A) securing the motor mounts to the frame. Do
not tighten the motor mount capscrews at this
time.
NOTE: Refer to the parts manual for new screws
and nuts part numbers. Torque the screws to 130
ft-lbs. (176 Nm) where mentioned in step 12.
IMPORTANT: Engine mounting screws must be
installed from the bottom up (locknuts on top).
Fig. 110 - Engine Mounts
8. Remove the lifting equipment (B, Fig. 111) from
the engine.
Fig. 111 - Engine Lifting Device
Printed in U.S.A.
Engine
9. Install the hydrostatic pump to the rear of the
engine with the two capscrews (C, Fig. 112).
10. Install the two capscrews (D, Fig. 112) on the
bottom of the hydrostatic pump support mount
(not shown).
11. Remove the hydrostatic pump support device
(E, Fig. 112).
E
Fig. 112 - Hydrostatic Pump Mount
12. Tighten the three motor mount capscrews, wash-
ers, and nuts (F, Fig. 113) securely.
F
Fig. 113 - Rear Engine Mounts
95 50950457/A0719
Engine
13. Install the seven capscrews (G, Fig. 114) secur- 16. Install the braided engine ground wire (K, Fig.
ing the engine support plate (H, Fig. 114) to the 116) to the grounding lug (L, Fig. 116) on the
engine. frame.

G
H

Fig. 114 - Engine Support Plate Fig. 116 - Engine Ground

14. Install the starter motor’s positive cables (I, Fig.
115).
15. Install the starter motor’s ground electrical con-
nector (J, Fig. 115).
17. Connect the four main engine harness electrical
connectors (M, Fig. 117) to the engine.
M

J
Fig. 117 - Main Engine Harness Electrical
Connectors

Fig. 115 - Starter Motor Electrical Connections

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 Engine
18. Install the four capscrews (N, Fig. 118) securing 21. Install the fuel filter/water separator bracket (R,
the Engine Control Unit (ECU) (O, Fig. 118) to Fig. 120) to the machine with two nuts (S, Fig.
the machine. 120).

N S

Fig. 118 - Engine Control Unit Fig. 120 - Fuel Filter/Water Separator Bracket

19. Install the ECU ground wire (P, Fig. 119). 22. Connect the two electrical connectors (T, Fig.
121) to the fuel filter/water separator.
20. Connect the two ECU electrical connectors (Q,
Fig. 119) to the ECU.

Q
P T
T

Fig. 121 - Fuel Filter/Water Separator Connectors

Fig. 119 - Engine Control Unit Harness

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Engine
23. Install the fuel filter manifold and bracket (U, 25. Using an appropriate lifting device (X, Fig.
Fig. 122) to the machine with two capscrews (V, 124) to install the fuel tank (Y, Fig. 124) to the
Fig. 122). machine.

X
U

Fig. 122 - Fuel Filter Bracket Fig. 124 - Fuel Tank Support

24. Connect the three fuel hoses (W, Fig. 123) to 26. Install the five capscrews (Z, Fig. 125) securing
the fuel filter manifold. Tighten the hose clamps the fuel tank to the machine.
securely.

W
W
W

Fig. 125 - Fuel Tank Mounts

Fig. 123 - Fuel Filter Hoses

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27. Install the two nuts (A, Fig. 126) securing the 29. Connect the fuel supply hose (D, Fig. 128) to
power relay bracket (B, Fig. 126) to the fuel the fuel filter/water separator filter manifold.
tank. Tighten the hose clamp securely.

A D

Fig. 126 - Power Relay Bracket Fig. 128 - Fuel Supply Hose

28. Install the two capscrews securing the fuel pump 30. Connect the fuel return hose (E, Fig. 129) to
electrical wires (C, Fig. 127) to the fuel tank. the fuel filter manifold. Tighten the hose clamp
securely.

Fig. 127 - Fuel Pump Electrical Wires

Fig. 129 - Fuel Return Hose

31. Install the four capscrews (F, Fig. 130) securing

the hydraulic oil filter manifold (G, Fig. 130) to
the fuel tank.

Printed in U.S.A. 99 50950457/A0719

Engine
32. Connect the two hydraulic oil lines (H, Fig. 130) 34. Install the two capscrews (J, Fig. 132) securing
to the hydraulic oil filter manifold. Tighten the the DPF to the rear DPF bracket.
hydraulic oil lines securely.

H
G
H

Fig. 132 - DPF Rear Bracket

Fig. 130 - Hydraulic Oil Filter Manifold
35. Install the four capscrews (K, Fig. 133) and
33. Install the four capscrews (I, Fig. 131) securing P-clip (L, Fig. 133) securing the DPF rear
the diesel particulate filter (DPF) to the engine access cover (M, Fig. 133) to the fuel tank.
exhaust manifold.

L K

Fig. 133 - DPF Rear Access Cover

Fig. 131 - DPF Mount

Removal of the ROPS/FOPS safety latch will

place all of the weight of the ROPS/FOPS on
the gas struts. DO NOT allow anyone under the
ROPS/FOPS if the safety latch is disengaged.

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 Engine
36. Disengage the safety latch (N, Fig. 134) to 38. Connect the three DPF sensor electrical connec-
lower the rollover protection structure (ROPS)/ tors (P, Fig. 136) at the DPF.
falling object protection structure (FOPS).

Fig. 136 - DPF Sensor Electrical Connectors

Fig. 134 - ROPS/FOPS Safety Latch
39. Connect the air intake hose to the intake mani-
37. Install the two capscrews (O, Fig. 135) securing fold and tighten the hose clamp (Q, Fig. 137).
the DPF to the front DPF mount.

O
O

Fig. 137 - Air Intake Hose

Fig. 135 - DPF Front Mount

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Engine
40. Install the two capscrews (R, Fig. 138) securing 42. Install and secure the air filter housing cover (T,
the air filter housing to the machine. Fig. 140).

Fig. 138 - Air Filter Housing Mount Fig. 140 - Air Filter Housing

41. Install the secondary and primary air filters (S, 43. Install the four capscrews (U, Fig. 141) securing
Fig. 139) to the air filter housing. the fan shroud to the machine frame.

Fig. 139 - Air Filters Fig. 141 - Fan Shroud Mounts

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 Engine
44. Install the two capscrews (V, Fig. 142) securing 46. Connect the upper and lower hydraulic oil
the fuel line and oil dipstick mounting bracket to cooler hoses (X, Fig. 144) to the cooling pack-
the fan shroud. age. Tighten the hydraulic oil hoses securely.

X
V

Fig. 142 - Oil Dipstick Mounting Bracket Fig. 144 - Hydraulic Oil Cooler Lines

45. Install the six capscrews (W, Fig. 143) securing 47. Connect the lower radiator hose (Y, Fig. 145) to
the fan shroud to the cooling package. the radiator. Tighten the hose clamp securely.

Fig. 143 - Cooling Package Fig. 145 - Lower Radiator Hose

48. Connect the upper radiator hose (Z, Fig. 146)

and coolant overflow hose (A, Fig. 146) to the
radiator. Tighten the hose clamps securely.

Printed in U.S.A. 103 50950457/A0719

Engine
49. Install the two capscrews, securing the p-clips
(B, Fig. 146) to the cooling package.
B coolant hoses. Use absorbent mats to catch any
Z A
B
Fig. 146 - Coolant Overflow Hose
50. Fill the cooling system.
51. Install the positive and negative battery cables
to the battery.
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
52. Start the engine, check for proper engine opera-
tion, and inspect for leaks.
53. Shut off the engine.
54. Check all fluid levels. Add as necessary.
50950457/A0719
Radiator/Cooler Removal/
Installation
NOTE: Some loss of hydraulic fluid and engine
coolant will occur when disconnecting hydraulic and
dripping fluid when disconnecting hoses. Close all
openings using caps and plugs.
IMPORTANT: Always dispose of hydraulic fluid
and engine coolant according to environmental
laws, or take them to a recycling center for proper
disposal. DO NOT pour them onto the ground or
down a drain.
Radiator/Cooler Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Open the petcock (A, Fig. 147) and drain the
engine cooling system.
A
Fig. 147 - Radiator Petcock
3. Remove the two P-clips (B, Fig. 148) that
secure the coolant overflow hose (C, Fig. 148)
to the cooling package and set aside. Close all
openings using caps and plugs.
B
B
C
Fig. 148 - Coolant Overflow Hose
104 Printed in U.S.A.

4. Remove the upper radiator hose (D, Fig. 149)
from the radiator. Close all openings using caps
and plugs.
D
Fig. 149 - Upper Radiator Hose
5. Remove the lower radiator hose (E, Fig. 150)
from the radiator. Close all openings using caps
and plugs.
Fig. 150 - Lower Radiator Hose
Printed in U.S.A.
Engine
6. Remove the upper and lower hydraulic oil
cooler hoses (F, Fig. 151) from the cooling
package. Close all openings using caps and
plugs.
F
Fig. 151 - Hydraulic Oil Cooler Lines
7. Remove the six capscrews (G, Fig. 152) that
secure the cooling package to the fan shroud and
remove the cooling package from the machine.
Fig. 152 - Cooling Package
105 50950457/A0719
Engine
Radiator/Cooler Installation 3. Connect the lower radiator hose (C, Fig. 155) to
the radiator. Tighten the hose clamp securely.
1. Install the cooling package to the machine,
securing it to the fan shroud with the six cap-
screws (A, Fig. 153).

Fig. 155 - Lower Radiator Hose

4. Connect the upper radiator hose (D, Fig. 156) to

Fig. 153 - Cooling Package the radiator. Tighten the hose clamp securely.
2. Connect the upper and lower hydraulic oil
cooler hoses (B, Fig. 154) to the cooling pack-
age. Tighten the hydraulic oil hoses securely.

Fig. 156 - Upper Radiator Hose

Fig. 154 - Hydraulic Oil Cooler Hoses

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5. Install the coolant overflow hose (E, Fig. 157) Air Filter Housing Removal/
and two P-clips (F, Fig. 157) to the cooling
package. Tighten the hose clamp and capscrews
Installation
securely.
Air Filter Housing Removal
1. Remove the air filter housing cover (A, Fig.
158) to expose the air filter elements.
F
F
E
A

Fig. 157 - Coolant Overflow Hose

6. Fill the cooling system.

7. Start the engine and inspect for leaks. Fig. 158 - Air Filter Housing

8. Shut off the engine. NOTE: For ease of access to air filter housing
mounting hardware, removal of primary air filter is
9. Add coolant if necessary.
necessary.
2. Remove the primary air filter (B, Fig. 159) from
the air filter housing.

Fig. 159 - Primary Air Filter

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Engine
3. Remove the secondary air filter (C, Fig. 160) 5. Remove the two capscrews (F, Fig. 162) that
from the air filter housing. secure the air cleaner assembly to the machine
and remove the air filter housing from the
machine.

Fig. 160 - Secondary Air Filter

4. Loosen the intake hose clamp (D, Fig. 161) and Fig. 162 - Air Filter Housing
remove the intake hose (E, Fig. 161) from the
intake manifold.
Air Filter Housing Installation
1. Connect the intake air hose (A, Fig. 163) to
the intake manifold. Tighten the hose clamp
securely.
D

Fig. 161 - Intake Air Hose

Fig. 163 - Intake Air Hose

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 Engine
2. Install the two capscrews (B, Fig. 164) securing 4. Install the primary air filter (D, Fig. 166) to the
the air cleaner assembly to the machine. air filter housing.

Fig. 164 - Air Filter Housing Fig. 166 - Primary Air Filter

3. Install the secondary air filter (C, Fig. 165) to 5. Install and secure the air filter housing cover (E,
the air filter housing. Fig. 167) to the air filter housing.

Fig. 165 - Secondary Air Filter Fig. 167 - Air Filter Housing Cover

Printed in U.S.A. 109 50950457/A0719

Engine

Fan Shroud Removal/Installation 3. Remove the two P-clips (B, Fig. 169) that
secure the coolant overflow hose (C, Fig. 169)
NOTE: Some loss of hydraulic fluid and engine to the cooling package and remove the coolant
coolant will occur when disconnecting hydraulic and overflow hose. Close all openings using caps
coolant hoses. Use absorbent mats to catch any
and plugs.
dripping fluid when disconnecting hoses. Close all
openings using caps and plugs.
IMPORTANT: Always dispose of hydraulic fluid
and engine coolant according to environmental B
laws, or take them to a recycling center for proper B
disposal. DO NOT pour them onto the ground or C
down a drain.

Fan Shroud Removal

1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Open the petcock (A, Fig. 168) and drain the
engine cooling system.

Fig. 169 - Coolant Overflow Hose

4. Remove the upper radiator hose (D, Fig. 170)

from the radiator. Close all openings using caps
and plugs.

Fig. 168 - Radiator Petcock

Fig. 170 - Upper Radiator Hose

50950457/A0719 110 Printed in U.S.A.


5. Remove the lower radiator hose (E, Fig. 171)
from the radiator. Close all openings using caps
and plugs.
Fig. 171 - Lower Radiator Hose
6. Remove the upper and lower hydraulic oil
cooler hoses (F, Fig. 172) from the cooling
package. Close all openings using caps and
plugs.
F
Fig. 172 - Hydraulic Cooler Lines
Printed in U.S.A.
Engine
7. Remove the six capscrews (G, Fig. 173) that
secure the cooling package (H, Fig. 173) to the
fan shroud and remove the cooling package
from the machine.
Fig. 173 - Cooling Package
8. Remove the two capscrews that secure the fuel
hose and oil dipstick bracket (I, Fig. 174) to the
fan shroud.
9. Remove the four capscrews (J, Fig. 174) that
secure the fan shroud to the machine and
remove the fan shroud from the machine.
I
J J
Fig. 174 - Fan Shroud
111 50950457/A0719
Engine
Fan Shroud Installation 3. Install the cooling package (C, Fig. 177) to the
fan shroud with the six capscrews (D, Fig. 177).
1. Install the fan shroud to the machine securing it
with the four capscrews (A, Fig. 175).

A A C

Fig. 177 - Cooling Package

Fig. 175 - Fan Shroud
4. Connect the upper and lower hydraulic oil
2. Install the fuel hose and oil dipstick mounting cooler hoses (E, Fig. 178) to the cooling pack-
bracket (B, Fig. 176) to the fan shroud with the age. Tighten the hydraulic oil hoses securely.
two capscrews.

E
B

Fig. 178 - Hydraulic Cooler Lines

Fig. 176 - Oil Dipstick Mounting Bracket

50950457/A0719 112 Printed in U.S.A.

 Engine
5. Connect the lower radiator hose (F, Fig. 179) to 7. Connect the coolant overflow hose (H, Fig. 181)
the radiator. Tighten the hose clamp securely. and the two P-clips (I, Fig. 181) to the cooling
package.

I
I
H

Fig. 179 - Lower Radiator Hose

Fig. 181 - Coolant Overflow Hose
6. Connect the upper radiator hose (G, Fig. 180) to
the radiator. Tighten the hose clamp securely. 8. Fill the cooling system.
9. Start the engine and inspect for leaks.
10. Shut off the engine.
11. Add coolant if necessary.

Fig. 180 - Upper Radiator Hose

Printed in U.S.A. 113 50950457/A0719

Engine

Engine Fan Removal/Installation 4. Remove the coolant overflow hose (B, Fig. 183)
and two P-clips (C, Fig. 183) from the cooling
NOTE: Some loss of hydraulic fluid and engine package and move to the side. Close all open-
coolant will occur when disconnecting hydraulic and ings using caps and plugs.
coolant hoses. Use absorbent mats to catch any
dripping fluid when disconnecting hoses. Close all
openings using caps and plugs.
IMPORTANT: Always dispose of hydraulic fluid C
and engine coolant according to environmental C
laws, or take them to a recycling center for proper B
disposal. DO NOT pour them onto the ground or
down a drain.

Engine Fan Removal

1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Disconnect the negative battery cable then the
positive battery cable.
3. Open the petcock (A, Fig. 182) and drain the Fig. 183 - Coolant Overflow Hose
engine cooling system.
5. Remove the upper radiator hose (D, Fig. 184)
from the radiator. Close all openings using caps
and plugs.

A D

Fig. 182 - Radiator Petcock

Fig. 184 - Upper Radiator Hose

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 Engine
6. Remove the lower radiator hose (E, Fig. 185) 8. Remove the six capscrews (G, Fig. 187) that
from the radiator. Close all openings using caps secure the cooling package to the fan shroud and
and plugs. remove the cooling package from the machine.

Fig. 185 - Lower Radiator Hose Fig. 187 - Cooling Package Mounts

7. Remove the upper and lower hydraulic oil 9. Remove the four center capscrews (H, Fig.
cooler hoses (F, Fig. 186) from the cooling 188) that secure the fan blade (I, Fig. 188) to
package. Close all openings using caps and the engine and remove the fan blade from the
plugs. machine.

F
I

Fig. 186 - Hydraulic Oil Cooler Hoses Fig. 188 - Engine Fan Blade

Printed in U.S.A. 115 50950457/A0719

Engine
Engine Fan Installation 3. Install the fan belt (D, Fig. 191) and apply ten-
sion with the alternator tensioner (E, Fig. 191)
1. Loosen the alternator tensioner capscrews (A,
and tighten the alternator tensioner securely.
Fig. 189) to release tension on the fan belt to
ease fan blade installation.

D
A

E
A

Fig. 191 - Fan Belt

Fig. 189 - Alternator Tensioner
2. Install the fan (B, Fig. 190) to the engine, secur-
ing it with the four capscrews (C, Fig. 190).
4. Install the cooling package to the machine,
securing it to the fan shroud with the six cap-
screws (F, Fig. 192).

F
C

Fig. 192 - Cooling Package

Fig. 190 - Engine Fan Blade

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 Engine
5. Connect the hydraulic oil cooler hoses (G, Fig. 7. Connect the upper radiator hose (I, Fig. 195) to
193) to the cooling package. Tighten the hydrau- the radiator. Tighten the hose clamp securely.
lic oil hoses securely.

I
G

Fig. 195 - Upper Radiator Hose

Fig. 193 - Hydraulic Oil Cooler Hoses
8. Connect the coolant overflow hose (J, Fig. 196)
6. Connect the lower radiator hose (H, Fig. 194) to and two P-clips (K, Fig. 196) to the cooling
the radiator. Tighten the hose clamp securely. package.

K
K
J

Fig. 194 - Lower Radiator Hose Fig. 196 - Coolant Overflow Hose

9. Fill the cooling system.

10. Start the engine and inspect for leaks.

11. Shut off the engine.
12. Add coolant if necessary.

Printed in U.S.A. 117 50950457/A0719

Engine

Starter Removal/Installation 5. Remove the upper capscrew (C, Fig. 199) that
secures the starter to the engine.
Starter Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Disconnect the battery negative and positive
cables.
3. Disconnect the starter ground electrical connec-
tor (A, Fig. 197) at the starter.

Fig. 199 - Starter Upper Capscrew

6. Remove the lower capscrew (D, Fig. 200) that

secures the starter to the engine.

Fig. 197 - Starter Ground Electrical Connector

4. Disconnect the positive starter cables (B, Fig.

198) from the starter.

Fig. 200 - Starter Lower Capscrew

7. Remove the starter motor from the machine.

Fig. 198 - Starter Positive Cables

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Starter Installation 4. Connect the starter positive cables (C, Fig. 203)
to the starter.
1. Install the starter to the engine. Install the upper
starter mounting capscrew (A Fig. 201) but do
not tighten at this time.

C
A

Fig. 203 - Starter Positive Cables

5. Connect the starter ground electrical connector

Fig. 201 - Starter Upper Capscrew (D, Fig. 204).
2. Install the lower capscrew (B, Fig. 202) secur-
ing the starter to the engine.
3. Tighten both starter motor mounting capscrews
securely.

D
B
Fig. 204 - Starter Ground Connector

6. Connect the battery positive and negative

cables.
7. Start the engine to insure proper operation of the
Fig. 202 - Starter Lower Capscrew starter motor.
8. Shut off the engine.

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Battery Removal/Installation 5. Disconnect the engine door harness electrical

connector (D, Fig. 207).
Battery Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16
2. Disconnect the battery negative and positive
cables.
3. Remove the nut (A, Fig. 205) that secures the
battery mounting bracket (B, Fig. 205) and
remove the bracket from the machine.
D

Fig. 207 - Engine Door Harness

B
6. Remove the coolant overflow reservoir (E, Fig.
208) from the rear engine access door.

Fig. 205 - Battery Mounting Bracket

4. Remove the upper hydraulic oil cooler hose (C, E

Fig. 206) from the cooling package. Close all
openings using caps and plugs.

Fig. 208 - Coolant Overflow Bracket

C

Fig. 206 - Hydraulic Oil Cooler Hoses

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 Engine
7. Remove the engine door lower hinge pin (F, Fig. NOTE: The engine access door weighs approxi-
209). mately 100 lb (45 kg).
9. Support the rear engine access door (H, Fig.
211) with a appropriate lifting device (I, Fig.
211). Remove the rear engine access door from
the machine.
F

Fig. 209 - Lower Door Hinge

8. Remove the capscrew, washer, and nut (G, Fig.

210) that secure the engine door upper hinge to
the machine.
Fig. 211 - Rear Door Support

10. Remove the battery from the machine.

G
Battery Installation
1. Install the battery.
2. Install the battery with the battery mounting
bracket (A, Fig. 212), securing it to the machine
with the lock nut (B, Fig. 212).

Fig. 210 - Upper Door Hinge A

Fig. 212 - Battery Mounting Bracket

Printed in U.S.A. 121 50950457/A0719

Engine
3. Connect the upper hydraulic oil cooler hose (C, 5. Install and secure the upper rear engine access
Fig. 213) to the cooling package. door hinge nut, washer and capscrew (E, Fig.
215) to the machine.

Fig. 213 - Hydraulic Cooler Lines

Fig. 215 - Upper Door Hinge
4. Install the rear engine access door (D, Fig. 214)
to the machine. 6. Install the lower rear engine access door hinge
pin (F, Fig. 216).

D
F

Fig. 214 - Rear Door Support

Fig. 216 - Lower Door Hinge

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 Engine
7. Connect the engine door harness electrical con-
nector (G, Fig. 217).

Fig. 217 - Engine Door Harness

8. Install the coolant overflow reservoir (H, Fig.

218) securing it to the rear door with the hose
clamp. Tighten the hose clamp securely.

Fig. 218 - Coolant Overflow Bracket

9. Start the machine to ensure proper operation.

10. Turn off the machine.

Printed in U.S.A. 123 50950457/A0719

Engine

Troubleshooting Guide
The following troubleshooting guide lists potential engine problems, as well as possible causes and
remedies.

When a problem occurs, don’t overlook simple causes. A malfunction could be caused by something as sim-
ple as an empty fuel tank. After a mechanical failure has been corrected, be sure to locate the cause of the
problem. For further troubleshooting information, refer to the engine manufacturer’s manual.

IMPORTANT: DO NOT attempt to service or repair major components, such as the fuel injector pump,
unless authorized to do so by your Manitou dealer. Any unauthorized repair will void the warranty.

Problem Possible Cause Corrective Action

Blown Fuse Check circuit and replace fuse.
Dead Battery Charge or replace battery.
Battery disconnect switch in open position Place battery disconnect switch into closed position. Repair or
or malfunctioning replace if necessary.
Starter malfunction Contact dealer.
Operator not in operator’s seat Operator’s seat must be occupied for the engine to start.
Engine does not
turn over. Malfunctioning seat/restraint bar/door
Replace seat/restraint bar/door switch.
switch
Cab door open (if equipped) Close cab door.
Engine electronics logic error Contact dealer.
Engine fault code(s) displayed Contact dealer.
Check electrical connections / voltage to fuel pump. Contact
Fuel pump malfunction.
dealer.
Check battery and charge / replace as necessary - tighten battery
Engine cranking speed too slow
terminals.
Fuel tank empty Fill tank and vent fuel system if necessary.
Fuel filter plugged or restricted Change fuel filter.
Fuel paraffin separation in winter Use winter grade diesel fuel.
Tighten all threaded connections and clamps, replace fuel line as
Fuel line leak
Engine turns necessary.
over but will not Fuel shut-off solenoid not energizing
Check electrical connections / voltage to shut-off solenoid.
start. (interim Tier 4 engines only)
Fuel filter restricted / fuel hose restriction Replace filter / check for pinched fuel hose.
Fuel pump malfunction Contact dealer.
Water in the fuel filter Purse water from filter.
Fuel valve on water separator is in the OFF
Turn the valve to its ON position.
position
Engine fault code(s) displayed Contact dealer.

50950457/A0719 124 Printed in U.S.A.

 Engine

Problem Possible Cause Corrective Action

Engine too cold / ambient temperature too Pre-heating module malfunction; check connection and voltage
low and charge / replace as necessary. Install block heater.
Crankcase oil level incorrect Adjust oil level.
Cooling air circulation restricted With engine off, reposition shroud / contact dealer.
Fan shroud improperly positioned With engine off, reposition shroud / contact dealer.
Engine Improper oil grade or oil excessively dirty Change engine oil.
overheating Exhaust restricted Allow exhaust to cool; remove restriction.
Air filter restricted Replace filter(s)
Low coolant level Top off coolant.
Loose fan belt Tighten fan belt.
Dirty / restricted radiator Clean radiator.
Thermostat malfunction Replace thermostat.
Black smoke indicates poor and incomplete diesel fuel
Black smoke
combustion.
Exhaust exces-
Blue smoke Blue smoked indicates engine oil combustion.
sively smoky
White smoke indicates incomplete diesel fuel combustion or
White smoke
coolant in the combustion chamber.

Printed in U.S.A. 125 50950457/A0719

Engine

Engine Error Codes

50950457/A0719 126 Printed in U.S.A.

 Engine

Printed in U.S.A. 127 50950457/A0719

Engine

50950457/A0719 128 Printed in U.S.A.

 Engine

Printed in U.S.A. 129 50950457/A0719

Engine

50950457/A0719 130 Printed in U.S.A.

 Engine
SPN FM P-CODE PART STATE
102 10 P1673 EGR Low Pres. Sensor Malfunction Aftertreatment Error
105 10 P1676 Intake Air Temp. Sensor Malfunction Aftertreatment Error
110 10 P1674 Coolant Temp. Sensor Malfunction Aftertreatment Error
173 10 P1677 Exhaust Temp. Sensor Malfunction Aftertreatment Error
412 10 P1675 EGR Gas Temp Sensor Malfunction Aftertreatment Error
1209 10 P1679 EGR High Pres. Sensor Malfunction Aftertreatment Error
3242 10 P167E DPF Inlet Temp. Sensor Malfunction Aftertreatment Error
3250 10 P167A DPF Intermediate Temp Sensor Malfunction Aftertreatment Error
3609 10 P167C DPF High Pres. Sensor Malfunction Aftertreatment Error
4795 31 P226D DPF Substrate Removed Aftertreatment Error

Printed in U.S.A. 131 50950457/A0719

Engine

50950457/A0719 132 Printed in U.S.A.

 Chapter 6
HYDROSTATIC SYSTEM
Introduction/General Information
This section includes removal, installation, assem-
bly and adjustment procedures for the track travel
drive system components. Travel drive components
included in this section are shown on the following
pages.
A hydrostatic tandem pump assembly coupled
to the engine provides hydrostatic power for two
hydrostatic drive motors. The drive motors are
directly connected to sprockets that drive the tracks.
Each motor drives one track on either side of the
machine.
The tracks are automatically and properly tensioned
when the machine is running. Hydraulic power for
the track tension cylinders is supplied by charge
pressure from the hydrostatic pump.
Refer to “Hydraulic System Maintenance” on page
49 for regular hydrostatic drive system maintenance
information.
General Hydraulic Service Notes
Unless otherwise instructed, make sure the
hydraulic oil has cooled before servicing the
hydraulic equipment.
Relieve pressure from the hydraulic system
before servicing the hydraulic equipment.
• Plug/cap open hydraulic connections to prevent
contamination.
• Wipe oil from components so it will not be mis-
taken for an oil leak.
Printed in U.S.A.
• Do not damage the plating on the cylinder rods.
• Remove/replace cylinders with rods fully
retracted.
• Bleed air after installing hydraulic cylin-
ders. Refer to “Bleeding Air After Cylinder
Installation” on page 182.
• When installing components, clean joint sur-
faces. Wind sealing tape securely, leaving a
space of a thread or two from the tip of the
screw. The tape should overlap itself approxi-
mately 12 mm (1/2 in.).
Hydraulic Oil Analysis
Periodically test the hydraulic oil using an analy-
sis kit, to check the hydraulic system for possible
contamination. Simple, cost-effective hydraulic
oil analysis kits are available through Manitou
Americas.
Hydraulic oil contamination can severely dam-
age the hydraulic system, which may not be
covered under the product warranty.
Theory of Operation/How It
Works
Usually powered by a standard engine, the hydro-
static pump uses pressurized oil to move pistons in
the hydrostatic drive system. The movement of the
pistons transfers power to the hydrostatic motors,
which then engage the track drives on the machine.
133 50950457/A0719
Hydrostatic System

Hydrostatic System Components

Drive train (1 of 2)

15
3

14
39

A
44 28
19

35
3
3

34

24

13 4
52
50
43

42
51

7 33

7
4
37

1
5
22

11 A
40
6

1 ST MJ06-MORB06 14 Pump Hydraulic/Series 40/M25 37 Tube/Hyd -06 LH Drain

2 90 MJ06-MAORB06 15 Hose/10m3k x 38 39 Tube/Hyd -06 LH Brake
3 ST MJ10-MORB10 19 CS FL 1/2x1-1/2 C8ZY 40 Tube/Hyd -06 Brake
4 Tee MJ08-FJS08-MJ08 22 Hose/Hyd -08 x 27in 42 CS 7/16x3/4 C5ZY
5 Tee MJ06-MJ06-MJ08 24 Tube/Hyd -08 Drain 43 FW 3/8 AWZY
6 Tee MJ06-MJ06-MJ06 28 Drive Motor/400cc 44 FW 1/2 AWZY
7 ST MJ08-MORB10 33 Tube/Tank-Brake 50 90 MJ08-MAORB08
11 45 MJ06-MAORB04 34 Hose/Hyd -10 X 12.75 in 51 Valve Package
13 Support/Pump 35 Hose/Hyd -10 X 17.5 in 52 Tee RUN MJ08-MAORB06-MJ08

Fig. 219 - Drive Train Components (1 of 2)

50950457/A0719 134 Printed in U.S.A.

 Hydrostatic System
Drive train - (2 of 2)

28

38

23
3

36
3

36

1 ST MJ06-MORB06
3 ST MJ10-MORB10
23 Tube/Hyd -06 RH Drain
28 Drive Motor/400cc
36 Hose/Hyd -10 X 30.0 in
38 Tube/Hyd -06 RH Brake

Fig. 220 - Drive Train Components (2 of 2)

Printed in U.S.A. 135 50950457/A0719

Hydrostatic System
Track Drive

16

30

17

13

12
6 15 5
2
3
11 4 10 13
13
20
13
8

14
7

13
9

13
8

1 HLN INST 3/8 CZY 7 Center Bogie/6.42”/Triple Flange 14 CS 3/8x3 C8ZY

2 CS FL LOCK 5/16x3/4 C5ZY 8 Idler/10.39”/Single 15 HWHTRS Tap/R 5/16x3/4 CZY
3 Stop/Hyd/Cylinder 9 Weldmt/Front Idler Yolk 16 HN M14-2.00 C12 ZY DIN934
4 CS 3/8x7/8 C5Z SP 10 Weldment/Cylinder Stop 17 SHCS M14-2x40 C12.9 OCG SP DIN912
5 SHCS M16-1.50x25 F12.9 OCB SP 11 Counter Rotate/Plate/Cylinder 20 Cylinder/3.25 X 1.50/Tension
DIN912 12 Sprocket/72P/14 Tooth/Forged 30 Drive Motor/400cc
6 Plate/Service Cover 13 CS FL M16-2.00x40 8.8 ZY DIN6921

Fig. 221 - Track Drive Components

50950457/A0719 136 Printed in U.S.A.

 Hydrostatic System
Track Tension Circuit

18
4

Located in 25
Engine
Compartment

27
31 52
7
32
51
17
4
8 10
12

21

12

9
9 16

30

26
29
20
41
21

17
4 Tee MJ08-FJS08-MJ08 17 ST MJ04-MORB04 29 Hose/Hyd -04 X 22.5 in
7 ST MJ08-MORB10 18 Switch/Track Tension 30 Hose/Hyd -04 X 29 in
8 90 MJ04-MAORB04 20 Valve/Tensioner 31 Hose/Hyd -04 x 47 in
9 90 MJ08-MAORB06 21 Cylinder/3.25 X 1.50/Tension 32 Hose/Hyd -04 X 41 in
10 Plug MORB06 25 Tube/Hyd -08 Tension Drain 41 CB 1/4x2-1/2 C5ZY
12 Tee RUN MJ04-MAORB04-MJ04 26 Spacer/Valve 51 Valve Package
16 LN FL SERR 1/4 CZY 27 Tube/Hyd -08 Valve Pressure 52 Tee RUN MJ08-MAORB06-MJ08

Fig. 222 - Track Tension Circuit

Printed in U.S.A. 137 50950457/A0719

Hydrostatic System

Hydrostatic Pump Removal/ 3. Complete the mandatory safety shutdown

procedure.
Installation
4. With the engine off and the key on, operate the
NOTE: Some machines may vary slightly from
control handles in each direction to relieve the
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases. hydraulic system pressure.

NOTE: Label all hoses and note their locations 5. Remove the two capscrews, washers, and nuts
before disconnecting them to ensure correct (C, Fig. 224) securing the rollover protection
installation. structure (ROPS)/falling object protective struc-
ture (FOPS) (D, Fig. 224) to the machine.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
D
recycling center for proper disposal. DO NOT pour C
fluids onto the ground or down a drain.
C
Hydrostatic Pump Removal
1. Remove the attachment.

Fig. 224 - ROPS/FOPS Mounting Hardware

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
Always raise the ROPS/FOPS completely, allow-
service.
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.
2. Raise and support the lift arm (A, Fig. 223)
using the lift arm support device (B, Fig. 223).
6. Raise the ROPS/FOPS until the safety latch (E,
Fig. 225) is engaged.
B

Fig. 223 - Lift Arm Support Device

Fig. 225 - ROPS/FOPS Safety Latch

50950457/A0719 138 Printed in U.S.A.

 Hydrostatic System
7. Remove the two capscrews and two nuts (F, 11. Disconnect the hydraulic hose (L, Fig. 228) on
Fig. 226) connecting the travel control rods (G, the right side of the hydrostatic pump. Close all
Fig. 226) to the hydrostatic pump (H, Fig. 226). openings using caps and plugs.
Move the travel control rods to the side.
8. Remove the nut (I, Fig. 226) securing the cen-
tering device (J, Fig. 226) to the control valve
bracket. Separate the centering device from the
control valve bracket and set it aside.

H L
G

F
Fig. 228 - Hydrostatic Pump Right Side Hydraulic
I Hose
G
12. Turn off the vacuum if applied.
J
13. Remove the two capscrews and washers (M,
Fig. 226 - Travel Control Rods
Fig. 229) that secure the gear pump (N, Fig.
229) to the hydrostatic pump. Separate the gear
9. Drain or apply a vacuum to the hydraulic pump from the hydrostatic pump.
system.
10. Tag and disconnect the five hydraulic hoses (K,
Fig. 227) from the left side of the hydrostatic
pump. Close all openings using caps and plugs. N
M

Fig. 229 - Gear Pump Mounting Hardware

Fig. 227 - Hydrostatic Pump Left Side Hydraulic

Hoses

Printed in U.S.A. 139 50950457/A0719

Hydrostatic System
14. Support the hydrostatic pump with an appropri-
ate lifting device (O, Fig. 230).
15. Remove the two capscrews and washers (P, Fig.
230) that secure the bottom hydrostatic pump
bracket to the rear engine cover.
16. Remove the two capscrews and washers (Q, Fig.
230) that secure the hydrostatic pump to the rear
engine cover.
O
P
Fig. 230 - Hydrostatic Pump Mounting Hardware
NOTE: The hydrostatic pump weighs approxi-
mately 75 lb. (34 kg).
17. With the aid of an assistant, remove the hydro-
static pump from the machine.
50950457/A0719
Hydrostatic Pump Installation
NOTE: The hydrostatic pump weighs approxi-
mately 75 lb. (34 kg).
1. With the aid of an assistant, install the hydro-
static pump, securing it to the rear engine cover
with two capscrews and washers (A, Fig. 231).
Tighten the capscrews securely.
2. Install the two capscrews and washers (B, Fig.
231) that secure the bottom hydrostatic pump
bracket to the rear engine cover. Tighten the
capscrews securely.
A
Fig. 231 - Hydrostatic Pump Mounting Hardware
3. Remove the lifting device from the hydrostatic
pump.
NOTE: Remove and discard the gasket between
the gear pump and the hydrostatic pump. Replace
it with a new gasket before installation.
4. Install a new gasket on the gear pump.
140 Printed in U.S.A.

5. Install the gear pump, securing it to the hydro-
static pump with two capscrews and washers (C,
Fig. 232). Tighten the capscrews securely.
C
Fig. 232 - Gear Pump Mounting Hardware
6. Apply a vacuum to the hydraulic system if
applied during removal.
7. Connect the hydraulic hose (D, Fig. 233) to the
right side of the hydrostatic pump. Tighten the
hydraulic hose securely.
Fig. 233 - Hydrostatic Pump Right Side Hydraulic
Hose
Printed in U.S.A.
Hydrostatic System
8. Connect the five hydraulic hoses (E, Fig. 234) to
the left side of the hydrostatic pump. Tighten the
hydraulic hoses securely.
E
Fig. 234 - Hydrostatic Pump Left Side Hydraulic
Hoses
9. Turn off the vacuum if applied.
10. Fill the hydraulic system or remove the vacuum
equipment if applied.
11. Install the centering device, securing it to the
control valve bracket with a nut (F, Fig. 235).
Tighten the nut securely.
12. Install the two capscrews and nuts (G, Fig. 235)
connecting the travel control rods to the hydro-
static pump. Tighten the capscrews securely.
G
F
Fig. 235 - Travel Control Rods
141 50950457/A0719
Hydrostatic System
13. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (H, Fig. 236) and lower the
ROPS/FOPS.
Fig. 236 - ROPS/FOPS Safety Latch
14. Install two capscrews, washers, and nuts (I,
Fig. 237) that secure the ROPS/FOPS to the
machine. Tighten the capscrews and nuts
securely.
I
Fig. 237 - ROPS/FOPS Mounting Hardware
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
15. Start the engine and check for proper machine
operation. Inspect for leaks.
50950457/A0719
16. Disengage the lift arm support device (J, Fig.
238) and lower the lift arm.
J
Fig. 238 - Lift Arm Support Device
17. Install the attachment.
18. Stop the engine
19. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Hydrostatic Pump Drive Coupler
Removal/Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all case.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
142 Printed in U.S.A.
 Hydrostatic System
Hydrostatic Pump Drive Coupler 5. Remove the eight capscrews (F, Fig. 241) that
Removal secure the hydrostatic pump drive coupler (G,
Fig. 241) to the engine.
1. Remove the hydrostatic pump from the
machine. See “Hydrostatic Pump” in this sec-
tion for more information. F
G
2. Remove the three capscrews and nuts (A, Fig.
239) that secure the top of the engine mount
plate (B, Fig. 239) to the engine mount brace.
3. Remove the four capscrews and washers (C,
Fig. 239) that secure the engine mount plate to
the engine rear cover plate. Remove the engine
mount plate from the machine.

B
A Fig. 241 - Hydrostatic Pump Drive Coupling

C 6. Remove the hydrostatic pump drive coupler

from the machine.

Hydrostatic Pump Drive Coupler

Installation
1. Install the hydrostatic pump drive coupler (A,
Fig. 242), securing it to the machine using blue
thread locking compound and eight capscrews
Fig. 239 - Engine Mounting Plate (B). Tighten the capscrews securely.

4. Remove the two capscrews and washers (D, Fig.

240) that secure the engine rear cover plate (E, B
A
Fig. 240) to the engine. Remove the engine rear
cover plate from the machine.

D D

Fig. 242 - Hydrostatic Pump Drive Coupling

Fig. 240 - Engine Rear Cover Plate

Printed in U.S.A. 143 50950457/A0719

Hydrostatic System
2. Install the engine rear cover plate to the engine
using two capscrews and washers (C, Fig. 243).
Tighten the capscrews securely.
Bogie Wheels Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Bogie Wheel Removal

1. Remove the attachment.
C
C

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.
Fig. 243 - Engine Rear Cover Plate

3. Install the engine mount plate to the engine rear 2. Raise and support the lift arm (A, Fig. 245)
cover plate using four capscrews and washers using the lift arm support device (B, Fig. 245).
(D, Fig. 244). Tighten the capscrews securely.
4. Install the three capscrews and nuts (E, Fig.
244), secure the top of the engine mount plate B
to the engine mount brace. Tighten the nuts
securely.
A

Fig. 245 - Lift Arm Support Device

Fig. 244 - Engine Mounting Plate.

5. Install the hydrostatic pump. See “Hydrostatic

Pump” in this section for more information.

50950457/A0719 144 Printed in U.S.A.

 Hydrostatic System
3. With the engine running and the machine in 6. Raise and support the machine about 150 mm (6
park, remove the two capscrews (C, Fig. 246) in.) so the tracks are free to move.
that secure the track tension cylinder stop (D,
Fig. 246) on the side of the machine where the
bogie wheel is being removed. Remove the
track tension cylinder stop from the machine.
Keeps hands and feet clear from between the
track and the bogie wheels when removing the
bogie wheel. Crushing of body parts and ampu-
D tation can result.

7. Remove the two capscrews (G, Fig. 248) that

secure the bogie wheel (H, Fig. 248) to the
machine. Remove the bogie wheel from the
C machine.

Fig. 246 - Track Tension Cylinder Stop

4. Open the engine compartment. Press and hold

the lock button (E, Fig. 247) on the track tension
service switch (F, Fig. 247), and press the left G
G
side of the switch to set the track tension cylin-
ders into the service (retracted) position.
H

F Fig. 248 - Bogie Wheel Mounting Hardware

Fig. 247 - Track Tension Service Switch

5. When the track tension cylinders are in the ser-

vice (retracted) position, shut off the engine.

Use solid support blocking or appropriate jack

stands. Never rely on jacks or other inadequate
supports when maintenance work is being
done. Never work under any equipment sup-
ported only by jacks.

Printed in U.S.A. 145 50950457/A0719

Hydrostatic System
Bogie Wheel Installation 3. Once the track tension cylinder has returned to
the operating (extended) position. Install the
track tension cylinder stop (D, Fig. 251), secur-
ing it to the machine with the two capscrews (E,
Fig. 251). Tighten the capscrews securely.
Keeps hands and feet clear from between the
track and the bogie wheels when installing the
bogie wheel. Crushing of body parts and ampu-
tation can result.
D

1. Install the bogie wheel (A, Fig. 249) in posi-

tion on the machine, securing it with the two
capscrews (B, Fig. 249). Tighten the capscrews
securely. E

Fig. 251 - Track Tension Cylinder Stop

4. Operate the track drive back and forth to ensure

the track is properly seated.
B
B 5. Remove the jack stands and lower the machine
to the ground.
A
6. Disengage the lift arm support device (F, Fig.
252) and lower the lift arm (G, Fig. 252).

Fig. 249 - Bogie Wheel Mounting Hardware

F
2. Start the engine, open the engine compartment,
and press the right side of the track tension ser-
G
vice switch (C, Fig. 250) to set the track tension
cylinders into the operating (extended) position.

C
Fig. 252 - Lift Arm Support Device

7. Install the attachment.

8. Stop the engine.

Fig. 250 - Track Tension Service Switch

50950457/A0719 146 Printed in U.S.A.

 Hydrostatic System

Track Removal/Installation 4. With the engine running and the machine in

NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
Track Removal
1. Remove the attachment.
park, open the engine compartment. Press and
hold the lock button (E, Fig. 255) on the track
tension service switch (F, Fig. 255), and press
the left side of the switch to set the track tension
cylinders into the service (retracted) position.

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service. E

2. Raise and support the lift arm (A, Fig. 253) Fig. 255 - Track Tension Service Switch
using the lift arm support device (B, Fig. 253).
5. When the track tension cylinders are in the ser-
vice (retracted) position, shut off the engine.

A Use solid support blocking or jack stands.

Never rely on jacks or other inadequate sup-
ports when maintenance work is being done.
Never work under any equipment supported
only by jacks.

Fig. 253 - Lift Arm Support Device

6. Raise and support the machine about 150 mm (6
3. With the engine running and the machine in in.) so the tracks are free to move.
park, remove the two capscrews (C, Fig. 254)
securing the track tension cylinder stop (D, Fig.
254) on the side of the machine where the track
is being removed. Remove the track tension
cylinder stop from the machine.

Fig. 254 - Track Tension Cylinder Stop

Printed in U.S.A. 147 50950457/A0719
Hydrostatic System
7. Use a pry bar to pry and guide the track (G, Fig. Track Installation
256) off the front idler wheel (H, Fig. 256). NOTE: The track weighs approximately 200 lb.
(91 kg).

Keeps hands and feet clear from between the

track and the sprocket and idler/roller wheels
when installing tracks. Crushing of body parts
and amputation can result.

G
1. Using a hoist with a hook (A, Fig. 258), lift the
track (B, Fig. 258), and position it under the
rear idler wheel (C, Fig. 258). With the pry bar,
H
pry the track up and over the drive sprocket (D,
Fig. 258) until the sprocket teeth and track holes
align.
Fig. 256 - Front Idler Wheel

NOTE: The track weighs approximately 200 lb.

(91 kg).
8. Using a hoist with a hook (I, Fig. 257) and a B
pry bar, lift and guide the track off the drive A
sprocket (J, Fig. 257). Remove the track from
the machine.

C
D
I
Fig. 258 - Track Lifting Device

NOTE: The lugs on the inside of the track must

J be fully engaged by the drive sprocket.
2. Remove the lifting equipment from the track.

Fig. 257 - Track Lifting Device

50950457/A0719 148 Printed in U.S.A.


3. Use a pry bar to pry and guide the track over
the front idler wheel (E, Fig. 259) and under the
bogie wheels (F, Fig. 259).
E I
F
Fig. 259 - Front Idler Wheel
NOTE: Guides on the inside of the track must
straddle the front idler and inside the bogie wheels.
4. Make sure the track is fully engaged around the
front idler, inside the bogie wheels, and in the
drive sprocket.
5. Start the engine, open the engine compartment,
and press the right side of the track tension ser-
vice switch (G, Fig. 260) to set the track tension
cylinders into the operating (extended) position.
Fig. 260 - Track Tension Service Switch
Printed in U.S.A.
Hydrostatic System
6. Once the track tension cylinder has returned to
the operating (extended) position, operate the
track drive back and forth to ensure the track is
properly seated.
7. Install the track tension cylinder stop (H, Fig.
261), securing it to the machine with the two
capscrews (I, Fig. 261). Tighten the capscrews
securely.
Fig. 261 - Track Tension Cylinder Stop
8. Remove the jack stands and lower the machine
to the ground.
9. Disengage the lift arm support device (J, Fig.
262) and lower the lift arm (K, Fig. 262).
J
Fig. 262 - Lift Arm Support Device
10. Shut off the engine
149 50950457/A0719
Hydrostatic System

Track Tension Cylinder Removal/ 5. Tag and disconnect the two track tension cyl-
inder hydraulic hoses (C, Fig. 264). Close all
Installation openings using caps and plugs.
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
C
NOTE: Some loss of hydraulic fluid will occur C
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a Fig. 264 - Track Tension Cylinder Hoses
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain. 6. Turn off the vacuum if applied.
NOTE: The track tension cylinder weighs approxi-
mately 85 lb. (39 kg).
Track Tension Cylinder Removal
1. Remove the track. See “Track Removal” in this 7. Attach an appropriate lifting device (D, Fig.
section for more information. 265) to the front idler wheel (E, Fig. 265).
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
D
3. Remove the two capscrews (A, Fig. 263) that
secure the track tension cylinder access cover
(B, Fig. 263) to the machine.

Fig. 265 - Track Tension Cylinder Lifting Device

Fig. 263 - Track Tension Cylinder Access Panel

4. Drain or apply a vacuum to the hydraulic

system.

50950457/A0719 150 Printed in U.S.A.


8. Remove the capscrew (F, Fig. 266) that secures
the track tension cylinder stop (G, Fig. 266) and
the counter rotate plate (H, Fig. 266) to the track
tension cylinder (I, Fig. 266).
F
Hydrostatic System
Track Tension Cylinder Installation
The track tension cylinder is back heavy. Have
an assistant support the back of the track
cylinder as it is removed. Failure to follow this
information could result in personal harm or
machine damage.

10. With the aid of an assistant, install the track

tension cylinder (A, Fig. 267) in position on the
machine.
11. Install the counter rotate plate (B, Fig. 267) and
track tension cylinder stop (C, Fig. 267), secur-
I G
H ing it with the capscrew (D, Fig. 267). Tighten
the capscrew securely.

Fig. 266 - Track Tension Cylinder Stop

D
The track tension cylinder is back heavy. Have
an assistant support the back of the track
cylinder as it is removed. Failure to follow this
information could result in personal harm or
machine damage.

A C
9. With the aid of an assistant, remove the track B
tension cylinder from the machine.

Fig. 267 - Track Tension Cylinder Stop

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Hydrostatic System
12. Remove the lifting device (F, Fig. 268) from the
front idler wheel (G, Fig. 268).
F I
G
Fig. 268 - Track Tension Cylinder Lifting Device
13. Apply a vacuum to the hydraulic system, if
applied during the removal procedure.
14. Connect the two track tension cylinder hydraulic
hoses (H), Fig. 269 to the track tension cylinder.
Tighten the fittings securely.
H secure the sprocket (B, Fig. 271) to the travel
H
Fig. 269 - Track Tension Cylinder Hydraulic Hoses
50950457/A0719
15. Install the track tension cylinder access cover
(I, Fig. 270), securing it to the machine with the
two capscrews (J, Fig. 270). Tighten the cap-
screws securely.
Fig. 270 - Track Tension Cylinder Access Cover
16. Install the track. See “Track Installation” in this
section for more information.
Sprocket Removal/Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
Sprocket Removal
1. Remove the track. See “Track Removal” in this
section for more information.
2. Remove the six capscrews (A, Fig. 271) that
motor (C, Fig. 271) and remove the sprocket
from the machine.
A
B
Fig. 271 - Sprocket
152 Printed in U.S.A.
 Hydrostatic System
Sprocket Installation Front Idler Wheel Removal/
1. Install the sprocket (A, Fig. 272) in position on Installation
the travel motor (B, Fig. 272).
NOTE: Some machines may vary slightly from
2. Apply blue thread locking compound to the six what is shown in the photographs in this manual.
capscrews (C, Fig. 272). Install the six cap- Procedures are similar, however, in all cases.
screws securing the sprocket to the travel motor.
Tighten the capscrews securely. Front Idler Wheel Removal
1. Remove the track. See “Track Removal” in this
section for more information.
C
2. Attach an appropriate lifting device (A, Fig.
A 273) to the front idler wheel (B, Fig. 273).
3. Remove the two capscrews (C, Fig. 273) that
secure the front idler wheel to the track tension
cylinder (D, Fig. 273), and remove the front
B idler wheel from the machine.

A
Fig. 272 - Sprocket

3. Install the track. See “Track Installation” in this

C
section for more information.

B C
D

Fig. 273 - Front Idler Wheel

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Hydrostatic System
Front Idler Wheel Installation Travel Drive Motors
1. Install the front idler wheel (A, Fig. 274) in The travel motors (Fig. 275) are directly connected
position on the track tension cylinder (B, Fig. to sprockets that drive the tracks on both sides of
274), securing it with the two capscrews (C, Fig. the machine.
274). Tighten the two capscrews securely.
2. Remove the lifting device (D, Fig. 274) from the
front idler wheel.

Fig. 275 - Travel Motor

A C
B

Fig. 274 - Front Idler Wheel

3. Install the track. See “Track Installation” in this

section for more information.

Fig. 276 - Travel Motor Internal Schematic

Travel Motor Maintenance

Refer to “Travel Motor Gearbox Oil” on page 53
for travel motor lubrication and regular gearbox oil
maintenance information.

For detailed travel motor service information, refer

to the Manitou service manual “” [Manitou part # ].

Travel Motor Removal/Installation

NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

50950457/A0719 154 Printed in U.S.A.

 Hydrostatic System
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur Always raise the ROPS/FOPS completely, allow-
when disconnecting hydraulic hoses. Use absor- ing the safety latch to engage. Never allow any-
bent mats to catch any dripping fluid when discon- one to be under the ROPS/FOPS if the safety
necting hoses. Cap and plug hydraulic hoses after latch is not engaged.
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a 5. Raise the ROPS/FOPS until the safety latch (C,
recycling center for proper disposal. DO NOT pour Fig. 278) is engaged.
fluids onto the ground or down a drain.

Track Motor Removal

NOTE: The following procedure was performed C
on the left side travel motor.
1. Remove the track. See “Track Removal” in this
section for more information.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Remove the sprocket. See “Sprocket Removal” Fig. 278 - ROPS/FOPS Safety Latch
in this section for more information.
4. Remove the two capscrews, washers, and nuts 6. Drain or apply a vacuum to the hydraulic
(A, Fig. 277) securing the rollover protection system.
structure (ROPS)/falling object protective struc- 7. Tag and disconnect the two hydraulic hoses and
ture (FOPS) (B, Fig. 277) to the machine. remove the fittings (D, Fig. 279) at the back of
the travel motor (E, Fig. 279). Close all open-
ings using caps and plugs.
B
8. Tag and remove the two travel motor hydraulic
lines and fittings (F, Fig. 279) from the machine.
Close all openings using caps and plugs.
A

Fig. 277 - ROPS/FOPS Mounting Hardware

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Hydrostatic System
11. Turn off the vacuum if applied.
D NOTE: The track tension cylinder weighs approxi-
mately 75 lb. (35 kg).
E
D 12. With the aid of an assistant, support the travel
motor and remove the 10 capscrews and nuts
(J, Fig. 282) that secure the travel motor to the
machine. Remove the travel motor from the
machine.

Fig. 279 - Travel Motor Hydraulic Hoses and Lines

9. Disconnect the hydraulic line (G, Fig. 280) at

the brake solenoid valve (H, Fig. 280).

H
J

Fig. 282 - Travel Motor Mounting Hardware

Fig. 280 - Hydraulic Line at Brake Solenoid Valve

10. Disconnect the hydraulic line (I, Fig. 281) at the

hydraulic reservoir and set the hydraulic line
aside. Close all openings using caps and plugs.

Fig. 281 - Hydraulic Line at Hydraulic Reservoir

50950457/A0719 156 Printed in U.S.A.

 Hydrostatic System
Track Motor Installation
NOTE: The travel motor weighs approximately 75
D
lb. (35 kg).
1. Install the travel motor (A, Fig. 283) in position
on the machine.
2. Apply blue thread locking compound to the 10
capscrews (B, Fig. 283). Torque capscrews to C
131 ft-lbs (178 Nm).
3. With the aid of an assistant, install the 10 cap-
screws and nuts securing the travel motor to
the machine. Tighten the capscrews and nuts
securely.
Fig. 284 - Hydraulic Line at Brake Valve

Fig. 285 - Connect the hydraulic line (E, Fig.

286) to the hydraulic reservoir. Tighten the fitting
securely.

B A

Fig. 283 - Travel Motor Mounting Hardware E

4. Turn the vacuum on, if applied during the

removal.
5. Connect the hydraulic line (C, Fig. 284) to the
brake solenoid valve (D, Fig. 284). Tighten the Fig. 286 - Hydraulic Line at Hydraulic Reservoir
fitting securely.
6. Install the four hydraulic fittings and two
hydraulic lines (F, Fig. 287) to the travel motor.
Tighten the hydraulic fittings and lines securely.
7. Connect the two hydraulic hoses (G, Fig. 287)
to the travel motor. Tighten the hydraulic hose
fittings securely.

Printed in U.S.A. 157 50950457/A0719

Hydrostatic System
G
F
Fig. 287 - Travel Motor Hydraulic Hoses and Lines
8. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (H, Fig. 288).
H (K, Fig. 290) that secure the ROPS/FOPS (L,
Fig. 288 - ROPS/FOPS Safety Latch
9. Lower the ROPS/FOPS (I, Fig. 289), securing it
to the machine with the two capscrews, washers,
and nuts (J, Fig. 289). Tighten the capscrews
and nuts securely.
50950457/A0719
I
J
Fig. 289 - ROPS/FOPS Mounting Hardware
10. Install the sprocket. See “Sprocket Installation”
for more information.
11. With the engine off and the key on, operate the
joysticks in each direction to relieve the hydrau-
lic pressure.
12. Remove the two capscrews, washers, and nuts
Fig. 290) to the machine.
K
Fig. 290 - ROPS/FOPS Mounting Hardware
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.
158 Printed in U.S.A.

13. Raise the ROPS/FOPS until the safety latch (M,
Fig. 291) is engaged.
Hydrostatic System
16. Lower the ROPS/FOPS (N, Fig. 293), secur-
ing it to the machine with the two capscrews,
washers, and nuts (O, Fig. 293). Tighten the
capscrews and nuts securely.

N
M

Fig. 291 - ROPS/FOPS Safety Latch

14. Check the travel motor hydraulic lines and hoses Fig. 293 - ROPS/FOPS Mounting Hardware
for any leaks.
15. Disengage the ROPS/FOPS safety latch (N Fig. 17. Check the hydraulic system fluid level. Add
292). hydraulic fluid if necessary.

Tracks
Inspect tracks daily for damage and wear.
N

Fig. 292 - ROPS/FOPS Safety Latch

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Hydrostatic System
Rubber Track Use Cautions and Tips
Carefully following the recommendations in this
section will result in better track wear performance.
If possible, avoid traveling over broken or
jagged stone, metal objects, on other sharp
objects that could damage or cut the tracks.
Inspect tracks and undercarriage components
for wear frequently. Worn components acceler-
ate track wear.
If possible, avoid traveling in areas with loose
rocks that could get stuck in the tracks, or
between the tracks and the track wheels.
Avoid using the machine in salt water areas.
Salt can corrode the metal cores in the tracks.
Clean any fuel, oil, salt, fertilizer or chemical
solvents that might get on the tracks. These
substances could corrode the metal cores in
the tracks.
Avoid traveling on roads immediately after
asphalting, or on other hot surfaces or over
fires. Damage to the tracks could result.
If climbing steps or cobblestone, avoid climbing
at an angle. Climb straight up the slope and do
not change course at the top of the slope.
When climbing slopes. Do not suddenly change
course at the point where the slopes starts.
Avoid traveling with one track on a slope or
other raised surface and the other track on a
flat surface.
Harder surfaces cause accelerated track and
undercarriage component wear. Avoid sharp
and spin turns on hard surfaces such as
concrete.
Avoid drops that cause severe blows to the
tracks.
High-speed operation and track slippage accel-
erate track and undercarriage component wear.
50950457/A0719
Avoid rubbing the sides of the tracks against
walls or other vertical surfaces.
It is impossible to estimate track life because track
life is affected by operating conditions, maintenance
and application.
Due to varying applications, there is no wear guar-
antee on rubber tracks. As a “rule of thumb,” how-
ever, rubber track life expectancy for track loaders
in “dirt” applications can be up to 2 to 2-½ times the
normal life of a set of pneumatic tires on a skid-
steer loader.
IMPORTANT: Track damage caused by heavy
and/or abusive use is not covered under warranty.
Damaged tracks cannot be repaired and must be
replaced.
To extend track life, the IdealTrax™ track tension
is loosened when the engine is not running. When
the engine is started, the tracks are automatically
adjusted to the correct tension. Monitor the tracks
at startup to ensure the automatic track tensioning
system is working properly. Tracks running loose
can de-track. Over-tightened tracks can cause power
loss, excessive roller, idler bearing and sprocket
wear, and track tearing.
Tracks and undercarriage should be cleaned regu-
larly. Mud and/or debris buildup in the track rollers,
sprockets and/or undercarriage structure can accel-
erate track wear. It prevents proper engagement
between the mating surfaces of sprocket teeth and
track links, can cause the tracks to be crowded off
the rollers, and may prevent roller rotation, leading
to roller and/or track failure. IdealTrax™ makes
cleaning tracks and undercarriage easier due to
increased clearance provided when the machine is
off and tension on the tracks is relaxed.
Constant operation on slopes, side hills, crowns and
depressions accelerates guide lug, idler, roller, and
sprocket wear. Avoid cutting across slopes. Instead,
drive up or down them. It is best to climb straight
up or down, and then turn when the machine is in a
more level location.
Alternate turning direction from one side to
the other. Always turning in one direction can
160 Printed in U.S.A.

accelerate sprocket tooth, track tread, guide lugs
and roller flange wear.
Unnecessary track slippage accelerates undercar-
riage and track wear and can cut tracks. Avoid track
slippage when driving into material and dig using
the lift/tilt hydraulics. Be aware when track slippage
occurs and adjust machine operation to prevent it.
Avoid making spin turns or pivot turns, which
accelerate wear and cause de-tracking. Always
make wide turns whenever possible.
Don’t allow the sides of the tracks to strike against
objects such as curbs or walls.
Avoid traveling with one track on a slope or a pro-
jecting object and the other track on a flat surface.
Travel with both tracks on a level surface if possi-
ble. Operating tracks with the outside or inside edge
of the track turned up on a curb, mound or stone can
crack tracks or shear the rubber.
Operate slowly and carefully. High-speed opera-
tion accelerates wear on all undercarriage and track
components.
Hydrostatic System
cores in the rubber tracks. If these materials come in
contact with the tracks, flush the tracks and under-
carriage with clean water to remove the damaging
materials.
Avoid operating in job sites where there are sharp
objects, such as jagged rocks or broken concrete,
which can damage the lug surface of the tracks. Use
common sense when operating in conditions which
are potentially damaging to rubber tires, because the
same conditions are damaging to rubber tracks as
well. Damaged tracks cannot be repaired and must
be replaced, and are not warrantable for failures
under these conditions.
Excessively worn undercarriage components will
damage tracks. Monitor these components to ensure
maximum track life. If replacing tracks, replace any
worn undercarriage components at the same time.
Listen for unusual or loud track/undercarriage
noises during operation. Loud/unusual noises often
indicate worn tracks/undercarriage.

Avoid traveling or operating on broken stone, jag-

ged base rock, iron rods, scrap iron or other recy-
cling-type materials. Rubber tracks are not intended
for these surfaces.

Working in heavily stone-laden soils or conditions

can cause damage or de-tracking due to stones
becoming lodged in the idler or drive sprockets.

Rubber tracks are not intended for use in quarry,

recycling or demolition applications.

Rubber track loaders are not intended for use with

cold planers.

Harder surfaces cause accelerated wear on track

treads, links, rollers, idlers, sprockets and other
undercarriage components. To minimize wear, avoid
routinely driving and turning on hard surfaces like
asphalt and concrete.

Avoid allowing fuel, oil, salt or fertilizer to get on

the tracks. These substances can corrode the metal

Printed in U.S.A. 161 50950457/A0719

Hydrostatic System
Sprocket Tooth Wear and Track Life
Worn sprockets are a typical cause of track damage
and abnormal track noise. Check for sprocket wear
often. Sprocket wear (B, Fig. 294) normally occurs
along the sides and crests of the sprocket teeth (C).
Use the sprocket tooth wear gauge (A - Manitou
part # 50323051),), included with the machine, to
determine exact sprocket tooth wear:
when ordering. Rotating sprockets by swapping
them from one side to the other can extend their
service life, provided the wear is limited to one
direction of travel.
IMPORTANT: New tracks perform better and
last longer with new sprockets because the mating
surface profiles are matched
Always replace sprocket mounting hardware
when replacing or re-attaching sprockets.

B
Track Replacement

A Keeps hands clear from between the track and

C the idler when installing tracks. Crushing of
body parts and amputation can result.

1. With the machine running and the drive system

B not moving, remove tension cylinder stop (K,
Fig. 295) on the side on the machine with the
track to be replaced.

Fig. 294 - Sprocket Tooth Wear Gauge

• Hold the sprocket tooth wear gauge (A) against

the sprocket teeth at the centerline of the
sprocket as shown in the photograph. Wear
gauge (A) has the same profile as the teeth on a
new sprocket.
NOTE: The sprocket tooth wear gauge is dou-
ble sided; one side is marked “16T” and is used K
for checking 16 tooth sprockets, the other side is
marked “17T” and is used for checking 17 tooth
sprockets.
• Sprocket wear is considered excessive if 4mm
Fig. 295 - Tension Stop Cylinder
(1/ 8”) of material is worn from any point along
the sprocket tooth profile. 2. With the machine running and the drive sys-
• Worn sprockets cannot be repaired and should tem not moving, open the engine compartment.
be replaced. Refer to the parts manual for your Press and hold the red lock button (P, Fig. 296)
machine for sprocket service part numbers on the track tension service switch, press the
50950457/A0719 162 Printed in U.S.A.

switch to set the track tension cylinders into the
service (retracted) position.
P
Fig. 296 - Track Tension Switch
3. When the track tension cylinders are in the ser-
vice (retracted) position, shut off the machine.
Use solid support blocking. Never rely on jacks
or other inadequate supports when mainte-
nance work is being done. Never work under
any equipment supported only by jacks.
4. Raise the machine about 150 mm (6.0”) so the
tracks are free to move.
5. Use a pry bar to pry/guide the old track at off
the front idler wheel.
6. Using a hoist with a hook installed and a pry
bar, lift/guide the old track off at the drive
sprocket. Remove the old track.
7. Using a hoist with a hook, lift the new track and
maneuver the track under the rear idler wheel at
using a pry bar and your foot.
IMPORTANT: Guides on the inside of the track
must straddle the rear idler.
8. Place a block under the new track to hold the
track against the bottom of the rear idler wheel.
9. Using a hoist with a hook and a pry bar, lift/
guide the new track onto the drive sprocket.
IMPORTANT: Lugs on the inside of the track
must be fully engaged by drive sprocket.
Printed in U.S.A.
Hydrostatic System
10. Using a pry bar and wedging blocks, pull/
guide the new track over the front idler wheel
and under the bottom rollers. Carefully, direct
an assistant to start the machine and direct the
assistant to operate the track drive slowly for-
ward/back to work the track over the front idler
wheel.
Keeps hands and feet clear from between the
track and the idler/roller wheels when installing
tracks. Crushing of body parts and amputation
can result.
NOTE: The tie-down bracket can be used as a
lever point for prying the track into place over the
front idler wheel.
IMPORTANT: Guides on the inside of the track
must straddle the front idler and bottom roller
wheels.
11. Be sure the new track is fully engaged around
the idler and roller wheels, and in the drive
sprocket, all the way around.
12. Remove any wedging blocks that were used to
guide the track.
13. Remove the block placed under the track.
14. Start the machine, open the engine compartment
and press the track tension service switch (P,
Fig. 296), to set the track tension cylinders into
the operating (extended) position.
15. Once the track tension cylinder has returned
to the operating (extended) position, re-install
cylinder stop (K, Fig. 295).
16. Operate the track drive forward/back to ensure
the track is properly seated. Adjust track posi-
tioning, if necessary.
17. Remove the blocking and lower the machine to
the ground.
163 50950457/A0719
Hydrostatic System
IdealTrax™ Track Tensioning System
The IdealTrax™ track tensioning system automat-
ically and properly tensions the tracks when the
machine is running. Hydraulic power for the track
tension cylinders is supplied by charge pressure
from the hydrostatic pump.
Track Tensioning Malfunctions
The track tension (pilot) valve routes pilot pressure
to the track tension cylinders for track tensioning.
A spool/solenoid in the valve is used to reverse
pilot flow to retract the tension cylinders for track
removal/replacement.
Possible causes of track tensioning system mal-
function could include, but are not limited to, the
following
• Low pilot pressure. Refer to “Hydrostatic
Charge Pressure Test and Adjustment” on page
132.
• Track tension cylinder internal leakage. Refer to
“Track Tension Cylinder Internal Leakage Test”
on page 159.
• Track tension (pilot) valve malfunction. Refer to
“Track Tension (Pilot) Valve Test” on page 160.
Track Tension Cylinder Internal Leakage
Test
IMPORTANT: This procedure requires two
people.
1. Remove screws (D, Fig. 271) securing track
tension cylinder covers (E). Remove covers (E).
Fig. 297 - Left Tension Cylinder Access Cover
50950457/A0719
IMPORTANT: To prevent contamination, ALWAYS
clean the area around hydraulic fittings before dis-
connecting hydraulic hoses or tubes.
2. Remove the hydraulic hose from tension cyl-
inder rod-end port on the cylinder valve block.
Cap or plug the hose.
NOTE: On either side, the rod-end port is the
most forward port (F, Fig. 298).
IMPORTANT: Caps/plugs MUST be able to with-
stand full hydraulic pilot pressure.
F
Fig. 298 - Tension Cylinder Rod End Port
3. Connect a hose to rod-end cylinder port (F, Fig.
298) and place the other end of the hose into a
suitable container to allow the hydraulic oil to
drain.
4. Sit in the operator’s seat and start the engine.
Have an assistant watch the hose in the
container.
5. If oil streams into the bucket, the tension cyl-
inder seals require replacement. Remove caps/
plugs and reconnect the hydraulic hose to the
port (F, Fig. 298) on the tension cylinder rod
end. Tighten securely.
164 Printed in U.S.A.
 Hydrostatic System

Troubleshooting
Problem Possible Cause Corrective Action
No response from Hydraulic oil viscosity is too heavy Allow longer warm-up or replace existing oil with the proper
either hydrostatic viscosity oil.
drive or the lift / tilt Hydraulic oil supply is too low Check for low oil level in the reservoir. Add oil.
systems Drive coupling failure Replace the coupling.
Parking brake is engaged Disengage the parking brake.
Hydraulic oil supply is low Check for low oil level in the reservoir. Add oil.
Traction drive will Check linkage connection at the control levers and neutral center-
Control rod linkage disconnected
not operate in ing mechanisms. Reconnect linkage.
either direction Low or no charge pressure Contact your dealer.
Hydrostatic pump(s) relief valve(s) are
Contact your dealer.
malfunctioning
Cycle lift and tilt cylinders to maximum stroke and maintain pres-
Air in hydraulic system sure for a short time to clear air from system. Also check for low
oil level in the reservoir, fill as needed.
Automatic parking brake is partially
Sluggish response engaged Contact your dealer.
to acceleration
Hydraulic oil supply is too low Check for low oil level in the reservoir. Add oil.
Low hydrostatic system charge pressure Contact your dealer.
Drive motor(s) or hydrostatic pump(s)
Contract your dealer.
have internal damage or leakage
Drive system overloaded continuously Improve efficiency of operation.
Lift / tilt or auxiliary system overloaded
Improve efficiency of operation.
continuously
Hydrostatic drive is Drive motor(s) or hydrostatic pump(s)
Contact your dealer.
overheating have internal damage or leakage
Oil cooler fins plugged with debris Clean oil cooler fins.
Machine operated in a high-temperature
Reduce duty cycle; improve air circulation.
area with no air circulation
Allow longer warm-up or replace existing oil with the proper
Hydraulic oil viscosity is too heavy
viscosity oil.
Cycle lift and tilt cylinders to maximum stroke and maintain pres-
Hydrostatic (drive)
Air in hydraulic system sure for a short time to clear air from system. Also check for low
system is noisy
oil level in the reservoir, fill as needed.
Drive motor(s) or hydrostatic pump(s)
Contact your dealer.
have internal damage or leakage
Rear hydrostatic pump arm control shaft
Contact your dealer.
Right side doesn’t key is missing
drive in either Relief valves on rear hydrostatic pump
Contact your dealer.
direction. Left side malfunctioning
operates normally. Control rod linkage to rear hydrostatic
Attach control rod linkage.
pump disconnected
Right side doesn’t Relief valve on rear hydrostatic pump is
Contact your dealer.
drive in one malfunctioning
direction Rear hydrostatic pump malfunctioning Contact your dealer.

Printed in U.S.A. 165 50950457/A0719

Hydrostatic System

Problem Possible Cause Corrective Action

Front hydrostatic pump arm control shaft
Left side doesn’t Contact your dealer.
key is missing
drive in either
Relief valves on front hydrostatic pump
direction. Right Contact your dealer.
malfunctioning
side operates
normally. Control rod linkage to front hydrostatic
Attach control rod linkage.
pump disconnected
Left side doesn’t Relief valve on front hydrostatic pump is
Contact your dealer.
drive in one malfunctioning
direction Front hydrostatic pump malfunctioning Contact your dealer.

50950457/A0719 166 Printed in U.S.A.

 Chapter 7
HYDRAULIC SYSTEM
Introduction/General Information
This section includes troubleshooting, testing,
removal, installation, and adjustment procedures for
hydraulic system components.
Power for lift arm lift/tilt and auxiliary work
hydraulics is provided by a gear pump.
An auxiliary hydraulics system with connections at
the front of the machine is provided for attachment
hookup.
Refer to “Lubricant Capacities” on page 41 for
recommended hydraulic fluids and capacities. Refer
to “Maintenance Schedule” on page 52 for rec-
ommended fluid and filter change intervals.
For component internal repair information not
covered in this manual, refer to the manufacturer’s
service manual for the specific hydraulic component
and/or contact Manitou service.
Refer to “Hydrostatic System” on page 133 for
information about the hydrostatic drive system.
Refer to ““” on page 210 for potential hydraulic
system problems, possible causes and remedies.
If a problem occurs, don’t overlook simple causes.
Malfunctions can be caused by something as simple
as a low hydraulic reservoir level.
DO NOT attempt to service or repair major
hydraulic system components unless autho-
rized to do so. Unauthorized repairs may void
the warranty.
Printed in U.S.A.
General Hydraulic Service Notes
Unless otherwise instructed, make sure the
hydraulic oil has cooled before servicing the
hydraulic equipment.
Relieve pressure from the hydraulic system
before servicing the hydraulic equipment.
• Plug/cap open hydraulic connections to prevent
contamination.
• Wipe oil from components so it will not be mis-
taken for an oil leak.
• Do not damage the plating on the cylinder rods.
• Remove/replace cylinders with rods fully
retracted.
• Bleed air after installing hydraulic cylinders.
• When installing components, clean joint sur-
faces. Wind sealing tape securely, leaving a
space of a thread or two from the tip of the
screw. The tape should overlap itself approxi-
mately 12 mm (1/2 in.).
Hydraulic Oil Analysis
Periodically test the hydraulic oil using an analy-
sis kit, to check the hydraulic system for possible
contamination. Simple, cost-effective hydraulic
oil analysis kits are available through Manitou
Americas.
167 50950457/A0719
Hydraulic System
• Do not twist O-rings. Hand-correct twists in
o-rings; do not use tools, which can damage
o-rings.
• Use care to prevent damage to seals during
Hydraulic oil contamination can severely dam- installation.
age the hydraulic system, which may not be
• Apply grease to the tip of oil seals to prevent
covered under the product warranty.
wear.
• Floating seals:
Hydraulic Hoses/Tubes • Wipe oil from O-rings and housings after
detaching floating seals.
• Be careful not to twist hoses. Use the hose
marking as a guide so hoses aren’t twisted. Use • Before installation, apply gear oil to the match-
two wrenches during removal/installation to ing face of the housing.
prevent twisting.
• To improve seating, rotate seals 2/3 revolution
• To prevent twisting, bends in a hose should all after installation.
be in the same direction.
• Support hoses having to bend along two differ-
ent planes, to prevent twisting.
• Be sure hoses do not contact each other after
tightening.
• Except when using seal tape, tighten hoses to
specified torque, loosen, and then re-tighten to
specified torque.
• When installing tubing, tighten nuts 1/4 to 1/2
turn after reaching a sharp torque rise point.
• Use elbows on hoses, as required, to avoid sharp
bends, especially at bends with a minimum
bending radius.
• Use adapters to make the hoses as straight as
possible.
• Hose length varies slightly at bends when pres-
surized; allow for this by not fastening hoses at
bends.
• Hose lengths should be slightly longer than nec-
essary. Hoses need ample slack to compensate
for elongation/retraction of +2% to -4% when
pressurized.

Seals
• Clean O-ring grooves and remove burrs, dirt/
dust from seals/O-rings.

50950457/A0719 168 Printed in U.S.A.

 Hydraulic System

Hydraulic System Components

Control Valve Circuit (Part 1 of 2)

1 90 MJ08-MAORB08 16 Oil Temp Switch 33 Tube/Tank Return

2 Clamp/Hose .50 x .41 Hole 17 90 MJ04-MAORB04 34 LN FL SERR 5/16 CZY
3 90 MJ10-FJS10 18 TEE BR MJ12-MJ12-MAORB12 38 Tube/Oil Filter
4 90 MJ10-MAORB10 19 Filter Assembly 40 Valve/Control 3 Spool
5 90 MJ06-MAORB06 21 LN FL SPIRALOCK 1/4 CZY 41 Plug/Pipe HS 1/4
6 ST MJ10-MORB10 22 Strap 42 CS 5/16x1-1/2 C5ZY
7 ST MJ10-MORB12 23 Valve Package 43 CB 5/16x2-1/4 C5ZY
8 90 MJ10-MAORB12 24 Valve/Sol SV10-24 10T 45 CB SN 5/16x1 C5ZY
9 Tee RUN MJ10-MAORB10-MJ10 25 Tube/Tank-brake 46 CB 1/4x2-1/4 C5ZY
10 Clamp/Hose .50 x .41 Hole 26 Tee RUN MJ08-MAORB06-MJ08 47 BHSCS 3/8x3/4 C8 OCG
11 Cap FJ08 28 Tee BR MJ08-MJ08-MAORB10 48 Plug/Pipe Sq Hd 1/8
12 Plate/Top Size 2 Twin Flat 29 Tube/Valve To Lift/Right 60 Filter Element
13 Clamp/Tube .62 Twin 30 Tube/Main Control/Lift 61 Assy/Filter Indicator
14 CS FL LOCK 5/16x3/4 C5ZY 31 Tube/Tilt Upper
15 ST MJ08-MORB10 32 TEST PORT-9/16-18 UNF

Fig. 299 - Control Valve Circuit (1 of 2) Components

Printed in U.S.A. 169 50950457/A0719

Hydraulic System
Control Valve Circuit (Part 2 of 2)

3 90 MJ10-FJS10 35 Clip, Hydraulic Line

4 90 MJ10-MAORB10 36 Tube/Auxiliary/Upper
6 ST MJ10-MORB10 37 Tube/Auxiliary/Lower
10 Clamp/Hose .50 x .41 Hole 39 Tube/Hyd -10 Tilt Lower
20 ST BLKHD MJ08-MJ08 44 CB 5/16x1-1/2 C5ZY
27 Tube/Valve To Lift/Left 45 CB SN 5/16x1 C5ZY
34 LN FL SERR 5/16 CZY

Fig. 300 - Control Valve Circuit (2 of 2) Components

50950457/A0719 170 Printed in U.S.A.

 Hydraulic System
Standard Hydraulics

1 90 MJ10-MJ10 7 Tube/Lift Lh
2 Cap FJ10 8 Tube/Control Valve/Lift
3 Plate/Top Size 2 Twin Flat 9 Tube/Lift Right
4 Clamp/Tube .62 Twin 10 CS 5/16x1-1/4 C5ZY
5 Clamp/Tube .50 Twin 11 CS 5/16x1-1/2 C5ZY
6 Tee MJ08-MJ08-MJ10

Fig. 301 - Standard Hydraulics Components

Printed in U.S.A. 171 50950457/A0719

Hydraulic System
Auxiliary Hydraulics Circuit - DPF Models

1 90 MJ10-MAORB10 9 LN FL SERR 5/16 CZY 17 CS 3/8x1-1/4 C5ZY

2 ST MJ10-MORB10 10 45 HB20-MAORB16 18 CB 5/16x3/4 C5ZY
3 O-Ring 152 N70 11 Tube/Hyd -10 Hyd Filter 19 LW 3/8 RZY
4 90 HB20-MAORB20 12 Clamp/Tube .625 20 Valve/Control 3 Spool
5 Pump/Gear Dbl 1.20/.84 13 Weldment/Filter Tube 21 ST MJ10-MORB12
6 Hose/Suction 14 Hose/Hyd -08 x 26in 22 Filter Assembly
7 Hose/Mp .50x23 15 Cushion/Cover .50 23 Filter Element
8 Clamp/T-Bolt 1.75 16 CS 1/4x1-3/4 C5ZY

Fig. 302 - DPF Model Auxiliary Hydraulics Circuit Components

50950457/A0719 172 Printed in U.S.A.

 Hydraulic System
Auxiliary Hydraulics Circuit - Non-DPF Models

1 90 MJ10-MAORB10 7 Hose/Suction 13 CS 3/8x1-1/4 C5ZY

2 ST MJ10-MORB10 8 Hydraulic Hose/Tube 14 LW 3/8 RZY
3 O-Ring 152 N70 9 Clamp/T-Bolt 1.75 20 Valve/Control 3 Spool
4 Clamp/Hose .75 x .41 Hole 10 LN FL SERR 5/16 CZY 21 ST MJ10-MORB12
5 90 HB20-MAORB20 11 45 HB20-MAORB16 22 Filter Assembly
6 Pump/Gear Dbl 1.20/.84 12 Hose/Hyd -08 X 28 in 23 Filter Element

Fig. 303 - Non-DPF Model Auxiliary Hydraulics Circuit Components

Printed in U.S.A. 173 50950457/A0719

Hydraulic System
Self-Leveling Circuit

1 90 MJ10-FJS10 6 Self Level Valve 11 CB 5/16x2-1/2 C5ZY

2 90 MJ10-MAORB10 7 LN FL CTR 5/16 CFZY 20 ST BLKHD MJ08-MJ08
3 ST MJ10-MORB10 8 Tube/Hyd -10 Self Level 21 90 MJ10-MAORB10
4 Tee RUN MJ10-MAORB10-MJ10 9 Tube/Hyd -08 Lift
5 Tee RUN MJ08-MAORB10-MJ08 10 Tube/Hyd -10 Lift

Fig. 304 - Self-Leveling Circuit Components

50950457/A0719 174 Printed in U.S.A.

 Hydraulic System
Lift Arm Auxiliary Hydraulics Circuit

1 Bracket, Coupler Retainer 20 Tube Assy/Aux Outer

6 LN CTR 3/8 CBZY 21 Tube Assy/ Aux Inner
7 90 MJ10-MAORB12 24 Hose/8m3k x 38
9 Coupler/Male FORB12 33 Clip, Hydraulic Line
10 Coupler/Female FORB12 43 HWHTRS Tap/R 5/16x3/4 CZY
11 Tie/Cable .50 x 12.90 Dual Black

Fig. 305 - Lift Arm Auxiliary Hydraulics Circuit Components

Printed in U.S.A. 175 50950457/A0719

Hydraulic System
Lift Arm Hydraulics Lift Circuit

2 ST MJ08-MORB08 17 Hose/MP .38x21.00 38 Fitting/Grease 1/8 PTF

3 90 MJ08-MAORB08 18 Tube Assy/Lift Cyl. 40 CS 3/8x2-1/2 C5ZY
6 LN CTR 3/8 CBZY 22 Clamp/Hose #44 Liner 41 CS 3/8x3 C5ZY
12 CYLINDER/LIFT 23 Pin/Pivot Lift
16 Hose/MP .38x22.50 28 Pin, Pivot Lift Cylinder

Fig. 306 - Lift Arm Hydraulics Lift Circuit Components

50950457/A0719 176 Printed in U.S.A.

 Hydraulic System
Lift Arm Hydraulics Tilt Circuit

3 90 MJ08-MAORB08 19 Hose/MP .38x32.00 33 Clip, Hydraulic Line

4 Tee MJ10-MJ10-MJ10 25 Hydraulic Cylinder/Tilt 34 Tube Clamps
5 90 MJ10-FJS10 26 Hose/Mp 1/2 x 42.5 35 FW 1-9/32
6 LN CTR 3/8 CBZY 27 Hose/Mp 1/2 x 31.5 36 Washer, Special
8 45 MJ08-MAORB08 28 Pin, Pivot Lift Cylinder 37 Washer Special
11 Tie/Cable .50 x 12.90 Dual Black 29 Pin, Tilt Cyl 39 Fitting/Grease 1/8 PTF 90
13 Hose/MP .38x14.50 30 Capscrew 5/8-18nf X 1 G/5 Plt 40 CS 3/8x2-1/2 C5ZY
14 Tube Assy/Liftarm Inner 31 Seal 42 Screw/THWH TC USL 3/8x1-1/2 CZY
15 Tube Assy/Liftarm Outer 32 Snap Ring

Fig. 307 - Lift Arm Hydraulics Tilt Circuit Components

Printed in U.S.A. 177 50950457/A0719

Hydraulic System

Main Pressure Test and 7. If the pressure reading is NOT within the spec-
ified pressures, adjust the pressure according to
Adjustment “Main Pressure Adjustment” on page 178.

Main Pressure Test Main Pressure Adjustment

IMPORTANT: This procedure requires two
people.
1. Remove any attachments from the attachment
hitch and lower the lift arm to the ground. BEFORE beginning this service procedure, shut
down the machine according to “Mandatory
2. Run the machine until the hydraulic oil Safety Shutdown Procedure” on page 16.
reaches operating temperature (approximately
60°C/140°F).
1. Raise the ROPS/FOPS according to “Raising
3. If necessary, use the hand throttle to set engine ROPS/FOPS” on page 281.
speed to low idle (1000 rpm).
2. Locate the relief valve adjuster (T, Fig. 309) at
4. Have an assistant connect a pressure gauge with the front of the main control valve.
a minimum capacity of 414 bar (6000 psi) into
male auxiliary hydraulics coupler (X, Fig. 308)
on the left lift arm.
T

A pressure gauge with a minimum of 414 bar

(6000 psi) is required. Damage may result to
gages if they are of insufficient capacity. Fig. 309 - Main Control Valve/Pressure Relief
Adjuster

NOTE: The main control valve is located under

the ROPS/FOPS on the front of the firewall on the
right side.
3. Remove cap on relief valve adjuster screw.
4. Loosen the small lock nut threaded on the valve.

Fig. 308 - Auxiliary Hydraulic Circuit Connections

5. Move the auxiliary control on the right joystick

to the full open to pressurize the circuit.
6. Have the assistant observe the pressure reading
on the gauge. The pressure reading should be
within the range of 190-200 bar (2756-2901 psi)
with the engine at low idle (1000 rpm). Fig. 310 - Loosen lock nut on relief valve

50950457/A0719 178 Printed in U.S.A.


5. With an Allen wrench, turn the adjuster screw
(U, Fig. 311) IN to increase pressure or OUT to
decrease pressure.
U
Fig. 311 - Allen Screw in the pressure adjustment
screw
6. Lower the ROPS/FOPS according to “Lowering
ROPS/FOPS” on page 282. Restart the engine
and perform another pressure test according to
“Main Pressure Test” on page 178.
7. After the pressure is within the correct PSI
range, tighten the locknut on the control valve
adjuster screw to secure the adjustment and
replace the cap over the adjuster screw.
8. If turning adjuster screw (C) does not change
the pressure reading, check for the following
problems:
NOTE: Possible hydraulic system malfunctions
include, but are not limited to, the following:
• Possible relief valve cartridge on the control
valve malfunction
• Possible hydraulic gear pump malfunction
Gear Pump Removal/Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when
Printed in U.S.A.
Hydraulic System
disconnecting hoses. Cap and plug hydraulic hoses
after disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
Gear Pump Removal
1. Park the machine where the hydrostatic pump
can be supported with an overhead hoist or sim-
ilar device.
2. Complete the “Mandatory Safety Shutdown
Procedure” on page 16. See “Safety Symbol
and Signal Words” on page 15.
3. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
4. Open the rear door at the rear of the machine.
5. Remove negative battery cable (C, Fig. 223)
from negative battery terminal (D). Secure neg-
ative cable (C) away from the battery.
6. Remove the two capscrews, washers, and nuts
(A, Fig. 312) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 312) to the machine.
B
A
Fig. 312 - ROPS/FOPS Mounting Hardware
179 50950457/A0719
Hydraulic System
10. Tag and disconnect the two hydraulic hoses (G,
Fig. 315) from the left side of the gear pump
(H, Fig. 315). Close all openings using caps and
Always raise the ROPS/FOPS completely, allow- plugs.
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

7. Raise the ROPS/FOPS until the safety latch (C, G

Fig. 313) is engaged.

C
Fig. 315 - Left Side Hydraulic Hoses

11. Disconnect the hydraulic suction hose (I, Fig.

316) from the right side of the gear pump. Close
all openings using caps and plugs.

Fig. 313 - ROPS/FOPS Safety Latch

I
8. Remove the two capscrews and nuts (D, Fig.
314) connecting the travel control rods (E, Fig.
314) to the hydrostatic pump (F, Fig. 314).
Move the travel control rods to the side.

F
E
Fig. 316 - Hydraulic Suction Hose
D
12. Turn off the vacuum if applied.

Fig. 314 - Travel Control Rods

9. Drain or apply a vacuum to the hydraulic

system.

50950457/A0719 180 Printed in U.S.A.

 Hydraulic System
4. Connect the hydraulic suction hose (B, Fig. 319)
13. Remove the two capscrews and washers (J, Fig. to the right side of the gear pump, securing it
317) securing the gear pump (K, Fig. 317) to the with the hose clamp. Tighten the hose clamp
hydrostatic pump (L, Fig. 317). securely.

L B

Fig. 317 - Gear Pump Mounting Hardware Fig. 319 - Hydraulic Suction Hose

14. Remove the gear pump from the machine. 5. Connect the two hydraulic hoses (C, Fig. 320)
to the left side of the gear pump. Tighten the
Gear Pump Installation hydraulic hoses securely.
NOTE: Remove and discard the gasket between
the gear pump and the hydrostatic pump. Replace
it with a new gasket before installation.
1. Install a new gasket between the gear pump and
the hydrostatic pump. C

2. Install the gear pump, securing it to the hydro-

static pump with two capscrews (A, Fig. 318)
and washers. Tighten the capscrews securely.

Fig. 320 - Left Side Hydraulic Hoses

A
6. Turn off the vacuum if applied.
7. Fill the hydraulic system or remove the vacuum
equipment if applied.

Fig. 318 - Gear Pump Mounting Hardware

3. Apply a vacuum to the hydraulic system if

applied during removal.
Printed in U.S.A. 181 50950457/A0719
Hydraulic System
8. Install the two capscrews and nuts (D, Fig. 321)
connecting the travel control rods to the hydro-
static pump. Tighten the capscrews securely.
D Fig. 323 - ROPS/FOPS Mounting Hardware
Fig. 321 - Travel Control Rods
9. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (E, Fig. 322) and lower the
ROPS/FOPS.
E
Fig. 322 - ROPS/FOPS Safety Latch
10. Install the two capscrews, washers, and nuts
(F, Fig. 323) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.
50950457/A0719
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
11. Start the engine and check for proper machine
operation. Inspect for leaks.
12. Stop the engine.
13. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Control Valve Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
182 Printed in U.S.A.
 Hydraulic System
Control Valve Removal 6. Remove the two capscrews, washers, and nuts
(C, Fig. 325) securing the rollover protection
1. Remove the attachment.
structure (ROPS)/falling object protective struc-
ture (FOPS) (D, Fig. 325) to the machine.

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.
D C

C
2. Raise and support the lift arm (A, Fig. 324)
using the lift arm support device (B, Fig. 324).

B
Fig. 325 - ROPS/FOPS Mounting Hardware

Always raise the ROPS/FOPS completely, allow-

ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

7. Raise the ROPS/FOPS until the safety latch (E,

Fig. 324 - Lift Arm Support Device
Fig. 326) is engaged.
3. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
4. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
E
5. Disconnect the negative and positive battery
cables.

Fig. 326 - ROPS/FOPS Safety Latch

8. Drain or apply a vacuum to the hydraulic

system.
9. Disconnect the electrical connector (F, Fig. 327)
from the rear of the control valve (G, Fig. 327).

Printed in U.S.A. 183 50950457/A0719

Hydraulic System
10. Disconnect the hydraulic line (H, Fig. 327) from 15. Disconnect the six hydraulic lines (P, Fig. 329)
the rear of the control valve. Close all openings from the top of the control valve. Close all
using caps and plugs. openings using caps and plugs.

F
H
P

Fig. 327 - Control Valve Rear Hydraulic Line Fig. 329 - Control Valve Hydraulic Lines

11. Remove the two cotter keys and pins (I, Fig. 16. Turn off the vacuum if applied.
328) connecting the lift and tilt control rods (J,
17. Remove two mount capscrews and nuts (Q, Fig.
Fig. 328) to the control valve (K, Fig. 328).
330) and remove the control valve and control
12. Remove the cotter key and pin (L, Fig. 328) valve mounting bracket from the machine.
connecting the lift arm foot pedal control cable
(M, Fig. 328) to the control valve.
13. Disconnect the hydraulic hose (N, Fig. 328)
from the front of the control valve. Close all
openings using caps and plugs.
14. Remove the nut (O, Fig. 328) securing the cen-
tering rod to the control valve bracket. Set the
centering rod aside.

K
Q Q

L N
O
M Fig. 330 - Control Valve Bracket Hardware

Fig. 328 - Lift/Tilt Control Rods

50950457/A0719 184 Printed in U.S.A.


Control Valve Installation
1. Lower the control valve and bracket (A, Fig.
331) into position, securing it to the machine
with the two capscrews and nuts (B, Fig. 331).
Tighten the nuts securely.
B
A
Fig. 331 - Control Valve Bracket Hardware
2. Apply a vacuum to the hydraulic system if
applied during removal.
3. Connect the six hydraulic lines (C, Fig. 332) to
the top of the control valve. Tighten the hydrau-
lic lines securely.
C M
Fig. 332 - Control Valve Top Hydraulic lines.
4. Install the lift arm foot pedal control cable (D,
Fig. 333), securing it to the control valve (E,
Fig. 333) with the pin and cotter key (F, Fig.
333).
5. Install the lift and tilt control rods (G, Fig. 333),
securing them to the control valve with the two
pins and cotter keys (H, Fig. 333).
Printed in U.S.A.
Hydraulic System
6. Connect the hydraulic hose (I, Fig. 333) to the
front of the control valve. Tighten the hydraulic
hose securely.
7. Install the centering rod, securing it to the
control valve bracket with the nut (J, Fig. 333).
Tighten the nut securely.
F I
J
D
G
Fig. 333 - Lift/Tilt Control Rods
8. Connect the hydraulic line (K, Fig. 334) to the
rear of the control valve (L, Fig. 334). Tighten
the hydraulic line securely.
9. Connect the electrical connector (M, Fig. 334)
to the rear of the control valve.
L
Fig. 334 - Control Valve Rear Hydraulic Line
10. Turn off the vacuum if applied.
11. Fill the hydraulic system or remove the vacuum
equipment if applied.
185 50950457/A0719
Hydraulic System
12. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (N, Fig. 335) and lower the
ROPS/FOPS.
Fig. 335 - ROPS/FOPS Safety Latch
13. Install the two capscrews, washers, and nuts
(O, Fig. 336) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.
O before disconnecting them to ensure correct
Fig. 336 - ROPS/FOPS Mounting Hardware
14. Connect the positive and negative battery
cables.
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
15. Start the engine and check for proper machine
operation. Inspect for leaks.
50950457/A0719
16. Disengage the lift arm support device (P, Fig.
337) and lower the lift arm (Q, Fig. 337).
P
Fig. 337 - Lift Arm Support Device
17. Install the attachment.
18. Stop the engine.
19. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Lift Solenoid Valve Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
Lift Solenoid Valve Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
186 Printed in U.S.A.

3. Disconnect the negative and positive battery
cables.
4. Remove the two capscrews, washers, and nuts
(A, Fig. 338) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 338) to the machine.
A E
Fig. 338 - ROPS/FOPS Mounting Hardware
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.
5. Raise the ROPS/FOPS until the safety latch (C,
Fig. 339) is engaged.
C
Fig. 339 - ROPS/FOPS Safety Latch
6. Drain or apply a vacuum to the hydraulic
system.
Printed in U.S.A.
Hydraulic System
7. Disconnect the electrical connector (D, Fig.
340) from the left side of the lift solenoid valve
(E, Fig. 340).
8. Disconnect the hydraulic line (F, Fig. 340) from
the left side of the lift solenoid valve. Close all
openings using caps and plugs.
D
Fig. 340 - Lift Solenoid Valve Hydraulic Line
NOTE: Due to the rigidity of the hydraulic lines,
the caps and plugs may need to be installed after
the solenoid is removed from the machine.
9. Disconnect the two hydraulic lines (G, Fig. 341)
from the T-fitting on top of the lift solenoid
valve. Close all openings using caps and plugs.
10. Turn off the vacuum if applied.
11. Remove the two nuts and mounting plate (H,
Fig. 341) from mounting studs. Remove the lift
solenoid valve from the machine.
G
H
Fig. 341 - Lift Solenoid T-Fitting
187 50950457/A0719
Hydraulic System
Lift Solenoid Valve Installation 6. Turn off the vacuum if applied.
NOTE: Due to the rigidity of the hydraulic lines, 7. Fill the hydraulic system or remove the vacuum
the caps and plugs may need to be removed prior equipment if applied.
to installing the solenoid on the machine.
8. Disengage the rollover protection structure
1. Install the lift solenoid valve (A, Fig. 342), (ROPS)/falling object protective structure
securing it to the machine with two nuts and the (FOPS) safety latch (F, Fig. 344) and lower the
mounting plate (B, Fig. 342). Tighten the nuts ROPS/FOPS.
securely.
2. Apply a vacuum to the hydraulic system if
applied during removal.
3. Connect the two hydraulic lines (C, Fig. 342)
to the top T-fitting. Tighten the hydraulic lines
securely. F

A
Fig. 344 - ROPS/FOPS Safety Latch

9. Install the two capscrews, washers, and nuts

(G, Fig. 345) securing the ROPS/FOPS to the
B
machine. Tighten the nuts securely.

Fig. 342 - Lift Solenoid Valve T-Fitting

4. Connect the hydraulic line (D, Fig. 343) to the

fitting on the left side of the lift solenoid valve.
Tighten the hydraulic line securely.
5. Connect the electrical connector (E, Fig. 343) to
the left side of the lift solenoid valve. G

D Fig. 345 - ROPS/FOPS Mounting Hardware

10. Connect the positive and negative battery

cables.

Fig. 343 - Lift Solenoid Valve Hydraulic Line

50950457/A0719 188 Printed in U.S.A.

 Hydraulic System

NEVER use your hands to search for hydraulic

fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.

11. Start the engine and check for proper machine

operation. Inspect for leaks.
12. Stop the engine.
Fig. 346 - Lift solenoid shown
13. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary. 5. If the attachment can be tilted, the tilt solenoid
(H, )Fig. 347 is malfunctioning.

Solenoid Valve Test

During normal operations, the solenoid valves
should prevent operation of the lift arm and drive H
functions if any of the safety interlock system
switches are open, for example:

• Operator not sitting on the seat.

• Restraint bar not lowered.

Test Procedure
1. Climb into the operator’s seat, lower the
restraint bar and start the engine.
2. Using the lift control, raise the lift arm off the
ground enough so that the attachment can be
tilted.
3. Raise the restraint bar, use the lift and tilt con-
trols (one at a time) to see if either function will
operate.
4. If the lift arm can be raised or lowered, the lift
solenoid (G, Fig. 346) is malfunctioning.
Fig. 347 - Tilt solenoid shown
6. Lower the restraint bar. BE SURE the parking
brake on the instrument panel is in the OFF
position.
7. Raise the restraint bar. Use the drive controls
(one at a time) to see if the tracks will move.
8. If the machine moves forward or backward, the
brake solenoid (I, Fig. 348) is malfunctioning.

Printed in U.S.A. 189 50950457/A0719

Hydraulic System
I
Fig. 348 - Brake solenoid shown
9. If any solenoid in the above tests appears to
be malfunctioning, test that solenoid coil as
follows.
BEFORE continuing this service procedure,
perform the following SAFETY procedure:
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support device.
(For detailed instructions, refer to the Safety
chapter of this manual.)
10. Have an assistant sit in the operator’s seat, lower
the restraint bar and turn the key switch to ON.
DO NOT start the engine.
11. Using a thin strip of steel (such as a pocket
ruler), check the suspected solenoid by moving
the steel strip close to the solenoid coil.
12. If the steel strip is magnetically attracted to the
solenoid coil, the coil works and the solenoid
cartridge may be causing the malfunction.
Tilt Solenoid Valve Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
50950457/A0719
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
Tilt Solenoid Valve Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Disconnect the negative and positive battery
cables.
4. Drain or apply a vacuum to the hydraulic
system.
5. Remove the wire tie (A, Fig. 349) and discon-
nect the tilt solenoid electrical connector (B,
Fig. 349).
6. Remove the upper tilt solenoid valve hydraulic
hose (C, Fig. 349). Close all opening using caps
and plugs.
C
A
B
Fig. 349 - Tilt Solenoid Valve Connector
190 Printed in U.S.A.
 Hydraulic System
7. Remove the tilt solenoid valve upper capscrew lower mounting capscrew and nut (B, Fig. 352).
(D, Fig. 350) and wiring P-clip (E, Fig. 350). Tighten the nut securely.
2. Apply a vacuum to the hydraulic system if
applied during removal.
D
3. Install the forward (C, Fig. 352) and left (D, Fig.
352) hydraulic lines at the T-fitting.
E

D A

Fig. 350 - Tilt Solenoid Valve P-Clip

8. Disconnect the forward (F, Fig. 351) and left (G,

Fig. 351) hydraulic line from the T-fitting. Close Fig. 352 - Tilt Solenoid Valve T-Fitting
all openings using caps and plugs.
4. Install the wiring P-clip (E, Fig. 353) and the
9. Remove the lower tilt solenoid valve capscrew upper tilt solenoid capscrew (F, Fig. 353) to the
(H, Fig. 351) and remove the tilt solenoid valve machine.
(I, Fig. 351) from the machine.

F
F
E

G I

Fig. 351 - Tilt Solenoid Valve T-Fitting

Fig. 353 - Tilt Solenoid Valve P-Clip
10. Turn off the vacuum if applied.
5. Install the upper tilt solenoid valve hydraulic
hose (G, Fig. 354).
Tilt Solenoid Valve Installation
6. Turn off the vacuum if applied.
1. Place the tilt solenoid valve (A, Fig. 352) on
the machine. At this time, secure it just with the

Printed in U.S.A. 191 50950457/A0719

Hydraulic System
7. Install the tilt solenoid electrical connector (H,
Fig. 354)and wire tie (I, Fig. 354).
G necting hoses. Cap and plug hydraulic hoses after
I recycling center for proper disposal. DO NOT pour
H
Fig. 354 - Tilt Solenoid Connector
8. Fill the hydraulic system or remove the vacuum
equipment if applied.
9. Connect the positive and negative battery
cables.
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
10. Start the engine and check for proper machine
operation. Inspect for leaks.
11. Stop the engine.
12. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Brake Solenoid Valve Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
50950457/A0719
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
fluids onto the ground or down a drain.
Brake Solenoid Valve Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Disconnect the negative and positive battery
cables.
4. Remove the two capscrews, washers, and nuts
(A, Fig. 355) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 355) to the machine.
B
A
Fig. 355 - ROPS/FOPS Mounting Hardware
192 Printed in U.S.A.
 Hydraulic System
9. Disconnect the hydraulic T-fitting (F, Fig. 358)
from the font of the brake solenoid valve. Close
all openings using caps and plugs.
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged. F

5. Raise the ROPS/FOPS until the safety (C, Fig.

356) latch is engaged.

C Fig. 358 - Brake Solenoid Valve Front Hydraulic

T-Fitting

10. Disconnect the hydraulic line (G, Fig. 359) from

the bottom of the brake solenoid valve. Close all
openings using caps and plugs.

Fig. 356 - ROPS/FOPS Safety Latch

6. Drain or apply a vacuum to the hydraulic

system.
7. Cut the wire ties (D, Fig. 357) and move the G
wiring harness away from the hydraulic lines.
8. Disconnect the two electrical connectors (E, Fig.
357) from the brake solenoid valve.
Fig. 359 - Brake Solenoid Valve Bottom Hydraulic
Line
D
E NOTE: Due to the rigidity of the hydraulic lines,
the caps and plugs may need to be installed after
the brake solenoid valve is removed from the
machine.
11. Tag and disconnect the hydraulic line (H, Fig.
D 360) from the rear top fitting on the brake sole-
E noid valve. Close all openings using caps and
plugs.
12. Tag and disconnect the two hydraulic lines (I,
Fig. 360) from the rear bottom T-fitting. Close
all openings using caps and plugs.
Fig. 357 - Brake Solenoid Valve Wiring Harness
13. Turn off the vacuum if applied.

Printed in U.S.A. 193 50950457/A0719

Hydraulic System
14. Remove the two nuts (J, Fig. 360) from the 4. Connect the hydraulic line (D, Fig. 361) to the
capscrews and remove the brake solenoid valve rear top hydraulic fitting on the brake solenoid
from the machine. valve. Tighten the hydraulic lines securely.

A
H D

I J
C B

Fig. 360 - Brake Solenoid Valve Rear Hydraulic

Fittings Fig. 361 - Brake Solenoid Valve Rear Hydraulic
Fittings

Brake Solenoid Valve Installation 5. Connect the hydraulic line (E, Fig. 362) to the
fitting on the bottom of the brake solenoid valve.
NOTE: Due to the rigidity of the hydraulic lines, Tighten the hydraulic line securely.
the caps and plugs may need to be removed prior
to installing the solenoid on the machine.
1. Install the brake solenoid valve (A, Fig. 361),
securing it to the machine using the capscrews
and nuts (B, Fig. 361). Tighten the nuts securely.
2. Apply a vacuum to the hydraulic system if
applied during removal. E
3. Connect the two hydraulic lines (C, Fig. 361)
to the rear bottom hydraulic fitting on the brake
solenoid valve. Tighten the hydraulic lines
securely.

Fig. 362 - Brake Solenoid Valve Bottom Hydraulic

Line

50950457/A0719 194 Printed in U.S.A.


6. Connect the front hydraulic T-fitting (F, Fig.
363). Tighten to the T-fitting securely.
Hydraulic System
11. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (I, Fig. 365) and lower the
ROPS/FOPS.

Fig. 363 - Brake Solenoid Valve Front Hydraulic

T-Fitting
Fig. 365 - ROPS/FOPS Safety Latch
7. Turn off the vacuum if applied.
8. Fill the hydraulic system or remove the vacuum 12. Install the two capscrews, washers, and nuts
equipment if applied. (J, Fig. 366) securing the ROPS/FOPS to the
machine. Tighten the nuts securely.
9. Connect the two wire connectors (G, Fig. 364)
to the brake solenoid valve.
10. Fasten the wiring harness to the hydraulic lines
using wire ties (H, Fig. 364).

H
G

H
G
Fig. 366 - ROPS/FOPS Mounting Hardware

13. Connect the positive and negative battery

cables.
Fig. 364 - Brake solenoid Wiring Harness

NEVER use your hands to search for hydraulic

fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.

Printed in U.S.A. 195 50950457/A0719

Hydraulic System
14. Start the engine and check for proper machine
operation. Inspect for leaks.
15. Stop the engine.
16. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Tilt Cylinder Test
If the bucket (or attachment) drifts down with the
tilt control in the NEUTRAL position, first check
the tilt cylinders for external leakage. If external
leakage is evident, a new seal kit should be installed
in the leaking cylinder(s). If no external leakage is
evident, check the tilt cylinders for internal leakage
according to the following procedure.
NOTE: When checking for drifting, the ignition
key MUST BE in the OFF position, operator in the
seat, and the restraint bar lowered. The maximum
allowable tilt cylinder circuit drifting with a loaded
bucket is 0.88” (22 mm) of cylinder extension in 15
minutes.
Test Procedure
BEFORE continuing this service procedure,
perform the following SAFETY procedure:
• Shut off the engine.
• Relieve hydraulic system pressure.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Load the bucket and allow it to rest on the
ground.
NOTE: To prevent contamination, ALWAYS clean
the area around hydraulic fittings before discon-
necting any hydraulic hose or tube.
50950457/A0719
2. Checking the right tilt cylinder: Remove the
lower hydraulic hose (K, Fig. 367) from the
right tilt cylinder and cap or plug the hose and
cylinder port. Caps or plugs MUST BE able to
withstand full hydraulic pressure.
K
Fig. 367 - Lower tilt cylinder hose on the right tilt
cylinder
3. Crack open (slightly loosen) the upper hydraulic
hose on the right tilt cylinder.
BEFORE raising a loaded bucket, BE SURE no
personnel are near the loader. Serious personal
injury can result if bucket drops suddenly or its
contents spill out.
4. Climb back into the operator’s seat, lower the
restraint bar, and start the engine.
5. Raise the lift arm enough for the bucket (or
attachment) to clear the ground.
6. Shut off the engine, turn the ignition key to the
ON position (engine OFF) and operate the tilt
control in both directions.
7. If the bucket drifts, the blocked tilt cylinder
has leaking piston seals. If it DOES NOT drift,
lower the lift arm and reconnect/re-tighten the
hydraulic hose(s) to the cylinder.
196 Printed in U.S.A.

8. Checking the left tilt cylinder: Remove the
lower hydraulic hoses (L, Fig. 368) on the left
tilt cylinder and cap or plug the cylinder ports.
Caps or plugs MUST BE able to withstand full
hydraulic pressure.
L
Fig. 368 - Lower tilt cylinder hose on the left tilt
cylinder
9. Connect the two hoses, just removed, together
with a straight fitting.
10. Crack open (slightly loosen) the inside upper
hydraulic hose on the left tilt cylinder.
11. Repeat steps 4 - 7 for the left tilt cylinder.
12. After both tilt cylinders have been tested, be
sure the hydraulic hoses are reconnected or
re-tightened.
NOTE: If both tilt cylinders have good seals, and
the bucket still drifts, the fault could be in either the
control valve or the self-leveling valve. Continue the
test procedure with step 13, below. Also, refer to
the Troubleshooting Guide in this chapter.
13. To determine if either the control valve or
self-leveling valve is faulty and causing the
bucket to drift, perform the “Self-Leveling
Valve Test” procedure in this chapter.
Printed in U.S.A.
Hydraulic System
Tilt Cylinder Removal/Installation
NOTE: The left side tilt cylinder is shown in this
procedure. The right side tilt cylinder procedure
may vary slightly but procedures are similar.
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
Tilt Cylinder Removal
1. Complete the mandatory safety shutdown
procedure.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Remove the attachment.
4. Drain or apply a vacuum to the hydraulic
system.
5. Disconnect the upper hydraulic hose (A) from
the tilt cylinder (B, Fig. 369). Close all openings
using caps and plugs.
Fig. 369 - Tilt Cylinder Upper Hydraulic Hose
197 50950457/A0719
Hydraulic System
6. Disconnect the bottom hydraulic hose (C, Fig. 9. Remove the upper tilt cylinder pin retaining
370) from the tilt cylinder. Close all openings capscrew (E, Fig. 372).
using caps and plugs.

C E

Fig. 372 - Upper Tilt Cylinder Pin Retaining

Fig. 370 - Tilt Cylinder Lower Hydraulic Hose Capscrew

7. Turn off the vacuum if applied. 10. Remove the upper tilt cylinder pin (F, Fig. 373)
from the machine.
8. Remove the lower tilt cylinder pin retaining
capscrew and nut (D, Fig. 371).

Fig. 373 - Upper Tilt Cylinder Pin

Fig. 371 - Lower Tilt Cylinder Pin Retaining

Hardware

50950457/A0719 198 Printed in U.S.A.

 Hydraulic System
11. With the aid of an assistant supporting the tilt 3. Install the upper tilt cylinder pin (B, Fig. 376).
cylinder, remove the lower tilt cylinder pin (G,
Fig. 374) from the machine.

Fig. 376 - Upper Tilt Cylinder Pin

Fig. 374 - Lower Tilt Cylinder Pin 4. Apply blue thread locking compound and install
the upper tilt cylinder pin retaining capscrew (C,
12. Remove the tilt cylinder from the machine. Fig. 377). Tighten the capscrew securely.

Tilt Cylinder Installation

1. With the aid of an assistant, place the tilt cylin-
der in position on the machine. C
2. Install the lower tilt cylinder pin (A, Fig. 375).

Fig. 377 - Upper Tilt Cylinder Pin Retaining

Capscrew

Fig. 375 - Lower Tilt Cylinder Pin

Printed in U.S.A. 199 50950457/A0719

Hydraulic System
5. Install the lower tilt cylinder pin retaining 8. Connect the upper hydraulic hose (F, Fig. 380)
capscrew and nut (D, Fig. 378). Tighten the nut to the tilt cylinder. Tighten the fitting securely.
securely.

F
D

Fig. 380 - Tilt Cylinder Upper Hydraulic Hose

Fig. 378 - Lower Tilt Cylinder Pin Retaining
9. Turn off the vacuum if applied.
Hardware
10. Fill the hydraulic system or remove the vacuum
6. Apply a vacuum to the hydraulic system if equipment if applied.
applied during removal.
7. Connect the lower hydraulic hose (E, Fig. 379)
to the tilt cylinder. Tighten the fitting securely.
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
E and penetrate the skin, causing serious injury.

11. Start the engine and check for proper machine

operation. Inspect for leaks.
12. Install the attachment.
13. Stop the engine.
14. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
Fig. 379 - Tilt Cylinder Lower Hydraulic Hose

50950457/A0719 200 Printed in U.S.A.


Lift Cylinder Test
If the lift arm drifts with the lift control in
NEUTRAL position, and the ignition key OFF,
first check the lift cylinders for external leakage. If
external leakage is evident, a new seal kit should be
installed in the leaking cylinder(s). If no external
leakage is evident, check the lift cylinders for inter-
nal leakage according to the following procedure.
NOTE: When checking lift arm for drifting, BE
SURE the ignition key is in the OFF position. The
maximum allowable lift cylinder drifting is 0.75” (19
mm) of cylinder retraction in 15 minutes.
Test Procedure
1. Remove the bucket or attachment from the
attachment bracket.
2. Raise the lift arm to maximum height. Then
release the lift cylinder lift arm support device
and slowly lower the lift arm to engage the
device.
BEFORE continuing this service procedure,
perform the following SAFETY procedure:
• Shut off the engine.
• Relieve hydraulic system pressure.
(For detailed instructions, refer to the Safety
chapter of this manual.)
Printed in U.S.A.
Hydraulic System
3. Remove the clamp securing the hydraulic tubes
to the lift cylinder on the side being tested.
Remove the hose (M, Fig. 381) on the base end
of the cylinder.
M
Fig. 381 - Hose to be removed on base end of the
lift cylinder
NOTE: To prevent contamination, ALWAYS clean
around hydraulic fittings before disconnecting any
hydraulic lines.
4. Disconnect the hydraulic tube (N, Fig. 382)
from the rod end port of the lift cylinder to be
tested.
N
Fig. 382 - Hydraulic tube to remove from the lift
cylinder
5. Install a plug on hydraulic tube. Attach a hose
to rod end port of the cylinder and run the other
end of the hose into a suitable container. Lower
the ROPS/FOPS.
6. Climb back into the operator’s seat, lower the
restraint bar and start the engine.
7. Hold the lift control in the RAISE position. If
the seals in the cylinder are defective and leak-
ing, oil will flow out of the rod-end port.
8. Lower the lift arm support device back against
the lift cylinder. Shut off the engine and move
201 50950457/A0719
Hydraulic System
the lift control in both directions to relieve
hydraulic pressure.
9. Reconnect the hydraulic tube to the cylinder,
then reattach the clamp around the hydraulic
tubes and cylinder.
NOTE: If neither lift cylinder shows signs of exter-
nal or internal leakage, and the lift arm still drifts,
the problem could be due to leaking hydraulic hose
fittings between the control valve and the lift cylin-
ders. Check all hydraulic hose fittings thoroughly.
The fault could also be in either the control valve
or the self-leveling valve. Continue the test proce-
dure with step 11. Also refer to the Troubleshooting
Guide in this chapter.
Lift Cylinder Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Remove the two capscrews, washers, and nuts
(A, Fig. 383) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 383) to the machine.
B

10. The other cylinder can be checked the same

way.
11. To determine if either the control valve or the
self-leveling valve is faulty, perform the “Main
Pressure Test and Adjustment” on page 178 A
procedure in this chapter.

Lift Cylinder Removal/

Installation Fig. 383 - ROPS/FOPS Mounting Hardware
NOTE: The left side lift cylinder is shown in this
procedure. The right side lift cylinder procedure
may vary slightly but procedures are similar.
NOTE: Some machines may vary slightly from Always raise the ROPS/FOPS completely, allow-
what is shown in the photographs in this manual. ing the safety latch to engage. Never allow any-
Procedures are similar, however, in all cases. one to be under the ROPS/FOPS if the safety
latch is not engaged.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.

50950457/A0719 202 Printed in U.S.A.

 Hydraulic System
4. Raise the ROPS/FOPS until the safety latch (C, 8. Disconnect the hydraulic hose (F, Fig. 386) from
Fig. 384) is engaged. the bulkhead fitting located under the lift cylin-
der. Close all openings using caps and plugs.

Fig. 384 - ROPS/FOPS Safety Latch

Fig. 386 - Lift Cylinder Bottom Hydraulic Hose
5. Remove the air cleaner. See “Air Cleaner” in the
engine section for more information. 9. Turn off the vacuum if applied.
6. Drain or apply a vacuum to the hydraulic 10. Remove the front lift cylinder pin retaining cap-
system. screw and nut (G, Fig. 387).
7. Disconnect the hydraulic hose (D, Fig. 385)
from the top of the lift cylinder (E, Fig. 385).
Close all openings using caps and plugs.
G

E
Fig. 387 - Front Lift Cylinder Pin Retaining
Hardware

Fig. 385 - Lift Cylinder Top Hydraulic Hose

Printed in U.S.A. 203 50950457/A0719

Hydraulic System
11. Remove the front lift cylinder pin (H, Fig. 388). 13. With the aid of an assistant, support the cylin-
der and remove the rear lift cylinder pin (J, Fig.
390).

H J

Fig. 388 - Front Lift Cylinder Pin

12. Remove the rear lift cylinder pin retaining cap- Fig. 390 - Rear Lift Cylinder Pin
screw and nut (I, Fig. 389).
14. Remove the lift cylinder from the machine.

I Lift Cylinder Installation

1. With the aid of an assistant, place the lift cyl-
inder in position on the machine and install the
rear lift cylinder pin (A, Fig. 391).

Fig. 389 - Rear Lift Cylinder Pin Retaining

Hardware

Fig. 391 - Rear Lift Cylinder Pin

50950457/A0719 204 Printed in U.S.A.


2. Install the rear cylinder pin retaining capscrew
and nut (B, Fig. 392). Tighten the nut securely.
B D
Fig. 392 - Rear Lift Cylinder Pin Retaining
Hardware
3. Apply grease to the front lift cylinder pin.
4. Raise the cylinder into position and install the
front lift cylinder pin (C, Fig. 393).
Fig. 393 - Front Lift Cylinder Pin
Printed in U.S.A.
Hydraulic System
5. Install the front cylinder pin retaining capscrew
and nut (D, Fig. 394). Tighten the nut securely.
Fig. 394 - Front Lift Cylinder Pin Retaining
Hardware
6. Apply a vacuum to the hydraulic system if
applied during removal.
7. Connect the hydraulic hose (E, Fig. 395) to the
bulkhead fitting located under the lift cylinder.
Tighten the hose securely.
Fig. 395 - Lift Cylinder Bottom Hydraulic Hose
205 50950457/A0719
Hydraulic System
8. Connect the hydraulic hose (F, Fig. 396) at
the top of the lift cylinder. Tighten the hose
securely.
Fig. 396 - Lift Cylinder Top Hydraulic Hose
9. Turn off the vacuum if applied.
10. Fill the hydraulic system or remove the vacuum
equipment if applied.
11. Install the air cleaner. See “Air Cleaner” in the
engine section for more information.
12. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (G, Fig. 397) and lower the
ROPS/FOPS.
Fig. 397 - ROPS/FOPS Safety Latch
50950457/A0719
13. Install the two capscrews, washers, and nuts
(H, Fig. 398) securing the ROPS/FOPS to the
machine. Tighten the nuts securely.
Fig. 398 - ROPS/FOPS Mounting Hardware
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
14. Start the engine and check for proper machine
operation. Inspect for leaks.
15. Stop the engine.
16. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
206 Printed in U.S.A.

Self-Leveling Valve Test
BEFORE continuing this service procedure,
perform the following SAFETY procedure:
• Shut off the engine.
(For detailed instructions, refer to the Safety
chapter of this manual.)
Test Procedure
1. Open the engine access cover and lock open the
rear door.
2. Loosen the jam nut on the self-leveling valve
adjuster screw (O, Fig. 399).
O Procedure” on page 16.
Fig. 399 - View of adjuster screw on the self-level-
ing valve
NOTE: For step 3, BE SURE to count and record
the number of turns, so the adjuster screw can be
returned to its original setting after the test.
3. With an Allen wrench, turn the adjuster screw in
(clockwise) until it bottoms out. The self-level-
ing valve is now disabled and will not affect the
tilt operations.
4. Perform steps 4 - 7 of the “Tilt Cylinder Test”
on page 196 procedure. If the bucket no longer
drifts, the self-leveling valve is defective. If the
bucket continues to drift, the control valve is
defective and in need of repair or replacement.
Printed in U.S.A.
Hydraulic System
Self-Leveling Valve Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use absor-
bent mats to catch any dripping fluid when discon-
necting hoses. Cap and plug hydraulic hoses after
disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
Self Leveling Valve Removal
1. Complete the “Mandatory Safety Shutdown
2. With the engine off and the key on, operate the
control handles in each direction to relieve the
hydraulic system pressure.
3. Open the rear engine access covers.
4. Drain or apply a vacuum to the hydraulic
system.
5. Remove the capscrew and P-clip (A, Fig. 400)
that secures the coolant overflow hose to the
upper right radiator mount bracket.
207 50950457/A0719
Hydraulic System
6. Disconnect the two upper hydraulic lines (B, 8. Disconnect the two lower hydraulic lines (D,
Fig. 400) from the self-leveling valve. Close all Fig. 402) from the self-leveling valve. Close all
openings using caps and plugs. openings using caps and plugs.

A D

D
Fig. 400 - P-clip Mount

7. Remove the upper right cooling package mount

capscrew (C, Fig. 401).
Fig. 402 - Lower Self-Leveling Valve

9. Turn off the vacuum if applied.

10. Remove the two capscrews (E, Fig. 403) that
secure the cooling package support bracket (F,
Fig. 403) and self-leveling valve (G, Fig. 403)
to the machine.

F
Fig. 401 - Cooling Package Capscrew G

Fig. 403 - Cooling Package Bracket

11. Remove the cooling package bracket and

remove the self-leveling valve from the
machine.

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 Hydraulic System
Self Leveling Valve Installation
1. Place the self-leveling valve (A, Fig. 404) and
the cooling package support bracket (B, Fig.
404) on the machine, securing it with the two
capscrews (C, Fig. 404). Tighten the capscrews
securely.

C
E

B
A
Fig. 406 - Lower Self-Leveling Valve

C 5. Install the two upper hydraulic lines (F, Fig.

407) to the self-leveling valve. Tighten the
hydraulic lines securely.
6. Install the coolant reservoir hose, securing it to
Fig. 404 - Cooling Package Bracket the upper right radiator mount bracket with the
P-clip and capscrew (G, Fig. 407). Tighten the
2. Install the upper right cooling package bracket capscrew securely.
capscrew (D). Tighten the capscrew securely.

F
F

Fig. 407 - P-clip Mount

Fig. 405 - Cooling Package Capscrew

3. Apply a vacuum to the hydraulic system if

applied during removal.
4. Install the two lower hydraulic lines (E, Fig.
406) to the self-leveling valve. Tighten the
hydraulic lines securely.

Printed in U.S.A. 209 50950457/A0719

Hydraulic System

NEVER use your hands to search for hydraulic

fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.

7. Turn off the vacuum if applied.

8. Fill the hydraulic system or remove the vacuum
equipment if applied.
9. Start the engine and check for proper machine
operation. Inspect for leaks.
10. Stop the engine.
11. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.

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 Hydraulic System

Troubleshooting
Problem Possible Cause Corrective Action
Hydraulic oil viscosity is too heavy Allow longer warm-up or replace with proper viscosity oil.
Check oil level in reservoir. If oil is low, check for an external
Lift / Tilt controls Hydraulic oil level is too low
leakage. Repair and add oil.
fail to respond
Solenoid valve(s) malfunctioning Check electrical connections to lift / tilt solenoid and repair.
Restraint bar or seat switch malfunction Check switches.
Restraint bar is raised Lower the restraint bar.
Check electrical connections to lock solenoid and repair
Lock solenoid malfunctioning connections as needed. If lock solenoid is still not function-
Auxiliary hydrau-
ing properly, contact your dealer.
lics do not function
Check electrical connections to the restraint bar switch and
Restraint bar switch malfunctioning repair connections as needed. If switch is still not function-
ing properly, contact your dealer.
Low engine speed Operate engine at higher speed.
Allow longer warm-up or replace existing oil with proper
Hydraulic oil viscosity is too heavy
viscosity oil.
Control linkage is restricted Check for control linkage restriction and adjust.
Hydraulic cylinder
action is slow Hydraulic oil leaking past cylinder piston seals Contact your dealer.
for lift and/or tilt Check electrical connections to the lift solenoid and repair
functions Solenoid valve(s) could be malfunctioning connections as needed. If lift solenoid valve is still not func-
tioning properly, contact your dealer.
Relief valve in control valve not functioning
correctly (squealing noise should be evident Contact your dealer.
while operating.)
Bucket does not
Self-leveling valve mis-adjusted or
level on the lift Contact your dealer.
malfunctioning
cycle
Seat or restraint bar switch malfunction Contact your dealer.
Jerky lift arm and Cycle lift / tilt cylinders to maximum stroke and maintain
Air in the hydraulic system
bucket action pressure for a short time to clear air from system.
Oil in hydraulic reservoir is low Check and add oil.
Oil leaking past tilt cylinder seals (internal or
Contact your dealer.
Bucket drifts external)
downward with tilt Self-leveling valve is malfunctioning Contact your dealer.
control in neutral Leaking hydraulic hoses, tubes or fittings Inspect hoses and tubes, tighten fittings. Replace hoses or
between control valve and cylinders tubes as needed.
Control valve is in its float position Take control out of float position.
Tilt cylinders are malfunctioning Contact your dealer.
No down pressure
on the bucket Relief valve in control valve not functioning
correctly (squealing noise should be evident Contact your dealer.
while operating.)
Check electrical connections to the tilt solenoid and repair
Bucket will not Tilt solenoid valve malfunctioning connections as needed. If tilt solenoid valve is still not func-
tilt, lift arm work tioning properly, contact your dealer.
properly Tilt spool in control valve not actuated or Check valve control linkage and / or tube connections to
leaking valve.

Printed in U.S.A. 211 50950457/A0719

Hydraulic System

Problem Possible Cause Corrective Action

Slow or no Pilot control lines have air in them Bleed pilot control lines from the main control valve.
response for Low charge pressure Contact your dealer.
bucket tilt, lift
works properly Linkage mis-adjusted between right foot pedal
(Hand/Foot Readjust for full travel without restriction.
and pilot valve
machines only)
Check electrical connections to the ift solenoid and repair
Lift arm does not Lift solenoid valve cold be malfunctioning connections as needed. If ift solenoid valve is still not func-
raise, bucket tilt tioning properly, contact your dealer.
work properly Lift spool in control valve not actuated or
Contact your dealer.
leaking.
Oil leaking past lift cylinder seals (internal or
Contact your dealer.
Lift arm doesn’t external)
maintain raised Oil leaking past lift spool in control valve Contact your dealer.
position with lift Self-leveling valve malfunctioning Contact your dealer.
control in neutral Leaking hydraulic hoses, tubes or fittings Inspect hoses and tubes, tighten fittings as needed.
between control valve and cylinders. Replace as needed.
Lift arm support device engaged Raise lift arm and disengage support device.
Check electrical connections to solenoid. Repair or replaced
Lift solenoid valve malfunctioning
Lift arm will not as needed.
lower or raise Restraint bar not lowered. Lower the restraint bar.
Check electrical connections to the switch. Replace switch
Seat or restraint bar switch malfunction
as needed.

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 Chapter 8
SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Hydrostatic/Hydraulic Schematic

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SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Chassis Electrical Schematic (1 of 2) (some overlap with 2 of 2 drawing)

50940610/A0719 214 Printed in U.S.A.

 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Chassis Electrical Schematic (2 of 2) (some overlap with 1 of 2 drawing)

Printed in U.S.A. 215 50940610/A0719

SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

ROPS/FOPS Electrical Schematic (1 of 2) (some overlap with 2 of 2 drawing)

50940610/A0719 216 Printed in U.S.A.

 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

ROPS/FOPS Electrical Schematic (2 of 2) (some overlap with 1 of 2 drawing)

Printed in U.S.A. 217 50940610/A0719

SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Start Box Jumper Electrical Schematic

50940610/A0719 218 Printed in U.S.A.

 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Chassis Harness Wiring Diagram - DPF Models

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SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

ROPS/FOPS Wiring Harness Diagram - DPF Models

50940610/A0719 220 Printed in U.S.A.

 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Door Harness Wiring Diagram

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SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Rear Wiper Harness Diagram

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 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

ROPS/FOPS Wiring Harness Diagram - Non-DPF Models

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SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Chassis Harness Wiring Diagram - Non-DPF Models

50940610/A0719 224 Printed in U.S.A.

 SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

Rear Lights Harness

Printed in U.S.A. 225 50940610/A0719

SCHEMATICS/WIRING DIAGRAMS - HYDROSTATIC/HYDRAULIC AND ELECTRICAL

50940610/A0719 226 Printed in U.S.A.

 Chapter 9
ELECTRICAL CONTROLS SYSTEM

Electrical Control System the engine coolant temperature sensor is monitored

General Information
The electronic control system in the machine uses a
combination of switches/relays and computer-based
components.
The computer-based components communicate with
each other using a Controller Area Network (CAN)
communication protocol.
by the ECU. If the sensor input rises above a set
level (engine overheat), a CAN message (110-x) is
broadcast on the system by the ECU, which is acted
upon by devices on the network (error codes/output
indicators on the display, possible engine de-rating,
etc.).
The CAN system also allows for connecting an
external computer for service and diagnostic
purposes.

CAN System General Information

The electrical system uses the SAE J1939 standard
for Controller Area Network (CAN) communication
and diagnostics.

CAN is a message-based protocol, allowing com-

munication between devices without the need for a
host computer. It provides communication between
control system components used throughout the
machine.

Devices communicate with each other through a

two-wire, serial bus connection (CAN high and
CAN low). The wires are 120 ohm nominal twisted
pair.

The main component of the CAN system is:

• Multi-function display
• ECU (Engine Control Unit)
• Control Interlock Module
CAN allows various devices on the network to
coordinate functions. For example, CAN messages
are acted upon by the ECU to coordinate engine
control.

Some CAN messages are based on feedback from

sensors or controls. Electrical input from a control
or sensor is converted to CAN messages which are
broadcast on the CAN network and are acted upon
by devices on the network. For example, input from
Printed in U.S.A. 227 50950457/A0719
Electrical Controls System

Control Modules
The electrical control modules monitor/control sev-
eral vital functions of the machine.

IMPORTANT: Periodically inspect connectors and

terminals for damage. Ensure no pins are bent and
no sockets are damaged. Replace damaged com-
ponents and securely reconnect connectors to the
control modules.

Interlock Control Module

The Interlock Control Module (Fig. 408) provides
logic, inputs and outputs for the electrical system. It
is located inside the ROPS/FOPS behind the right
metal access panel, near the operator’s right elbow.

GREEN LED
DIAGNOSTIC
INDICATORS (15) INPUT PIN DESCRIPTIONS:
OUTPUT PIN DESCRIPTIONS:
1. RED - KEYED POWER
1. BLUE - PARK BRAKE SOLENOID,
2. BLACK - GROUND
(5 AMP MAX CONTINUOUS)
3. WHITE - SEAT SWITCH
2. YELLOW - HYD RELAY,
RESTRAINT BAR SW

4. GREEN - RESTRAINT BAR SWITCH

PARK BRAKE LT

HYD TEMP SW
BRAKE SOL

CRANK SIGNAL
START RELAY
NOT USED

PARK BRAKE SW
HYD RELAY
SEAT BELT LT

IGN VOLT SENSE

DOOR SW
SEAT SW

NOT USED
+12VDC

(3 AMP MAX CONTINUOUS)

5. PURPLE - PARK BRAKE SWITCH
3. BROWN - SEAT BELT LIGHT,
6. GRAY - HYD TEMP SWITCH
(2 AMP MAX CONTINUOUS)
7. ORANGE - ENG TEMP SWITCH
4. GREEN - PARK BRAKE LIGHT,
8. GRAY - IGN VOLT SENSE
(2 AMP MAX CONTINUOUS)
9. WHITE - DOOR SWITCH
5. NOT USED
10. RED - CRANK SIGNAL
6. PINK - START RELAY,
11. NOT USED
(3 AMP MAX CONTINUOUS)
12. NOT USED
MATING CONNECTOR:
MATING CONNECTOR:
DEUTSCH PNB DT06-06S
DEUTSCH PNB DT06-12S

INPUT CONNECTOR
ALARM BUZZER 12 PIN DEUTSCH
OUTPUT CONNECTOR DT15-12PA
6 PIN DEUTSCH
DT15-06

Fig. 408 - Interlock Control Module LEDs/Pins

Several inputs/outputs are displayed on screens

on the multi-function display. Refer to “Interlock
Control Module Truth Table” on page 229 for
detailed MCU input/output information.

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 Electrical Controls System
Interlock Control Module Truth Table
Refer to truth table (Fig. 409) to analyze function-
ality of module. The module controls operation of
components listed in OUTPUTS section of truth
table. The ON or OFF state of various outputs is
determined by ON or OFF state of various input
conditions listed in INPUTS section of truth table.
The keyswitch must be in “ON” position.

• Example 1 (initial keyswitch “ON”): At initial

keyswitch ON, input LED “12-VDC In” should
light and internal seat belt alarm should sound
for five seconds.
The truth table section “Diagnostic LED States”
specifies active (ON) state of each input and output.

• Example: Active (ON) state of engine oil pres-

sure switch input (connector #1, pin #8) is a
low or grounded input. Active state of seat
switch input (connector #1, pin #3) is a high or
12-VDC input.

Fig. 409 - Interlock Control Module Truth Table

Printed in U.S.A. 229 50950457/A0719

Electrical Controls System
Engine Control Unit (ECU) CAN System Service/Computer
The Engine Control Unit (ECU) (A, Fig. 410) con- Connection
trols engine control logic and error reporting. It is
located on the back left riser, in front of engine fuel
Data Connector
filter (B).
The electrical system uses a six-pin Deutsch con-
nector data port (D, Fig. 412) and is located at the
right elbow of the operator in the cab behind a steel
cover with two thumb screws for computer diagnos-
tic/configuration connectivity.
A

B D

Fig. 410 - Engine Control Unit (ECU)

NOTE: Contact the engine manufacturer for more

information about the ECU and engine-specific
CAN messaging.
Fig. 412 - Data Port
Display/Indicators/Controls
Multi-Function Display CAN/Computer Connection Harnesses
The multi-function display (C, Fig. 411) is located Service Adapter Harness
at the top of the right instrument panel inside the
The service adapter harness is wired into the ROPS/
ROPS/FOPS.
FOPS harness [Manitou part # 50313191] and is
required to connect a computer to CAN system
control modules. It provides a connection bridge
between the data connector (Fig. 412) and other
computer connection harnesses dedicated to specific
areas in the CAN system:

Fig. 411 - Multi-Function Display

Refer to “” on page 231 for more information

about the multi-function display functional logic.

50950457/A0719 230 Printed in U.S.A.

 Electrical Controls System

Operation/Controller Area
Network (CAN) Functional
Organization
NOTE: The following pages provide operation/CAN
function details for each system component.
The following tables describe the basic functionality
of the control system logic. Entries in the following
table refer to multi-function display Input/Output
items described in “Inputs/Outputs Detail” on page
241
The control system uses the SAE J1939 standard
for Controller Area Network (CAN) communication
and diagnostics.
NOTE: The “Malfunction Causes” column in the
following tables contains information about possi-
ble function problems. In some cases, additional
information about specific malfunction conditions is
included
Fig. 413 - Service Adapter Harness Diagram

Yanmar Engine Connection Harness

The Yanmar engine connection (28, Fig. 413) har-

ness provides connection between the Yanmar ECU
and a computer, using Yanmar SMARTASSIST
software.

NOTE: Special SMARTASSIST software is

required. Contact Manitou service for more
information.

Printed in U.S.A. 231 50950457/A0719

Electrical Controls System
HydralocTM (Safety Interlock) Functional Detail
Table 5 - HydralocTM Safety Interlock Functional Detail

Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions Malfunction Causes

Safety interlock system recognizes Ignition switch malfunction.

Ignition switch in ON/RUN position. the operator’s seat is occupied. Electrical fault (switch,
Operator Seat switch CLOSED (seat occupied). NOTE: Safety interlock system components, connections or
Presence battery).
Seat Switch (green) on DIAGNOSTIC determines the operator’s seat is
INPUTS screen. NOT occupied if the seat switch is Component/safety interlock
open (seat not occupied). system malfunction.

Lift/tilt lockout solenoid in (pilot valve)

Engine is running (engine oil pressure turned off. (controls pilot flow to right
detected). control handle)

Seat switch CLOSED (seat occupied). Travel drive lockout valve solenoid
turned off (controls flow to left control
Seat Switch (green) on DIAGNOSTIC handle).
INPUTS screen. Electrical fault (switch/
Valve flow to travel motor parking components/connections).
Arm rests/restraint/safety bars down. brake turned off (releases parking
Enable Lift Arm
Swing-out door (if equipped) closed. brake against spring pressure). Component/safety interlock
Tilt and Lift, and
system malfunction.
Travel Device Restraint Bar (green) on NOTE: If the seat switch is opened
DIAGNOSTIC INPUTS screen. (seat not occupied), and/or either or Hydraulic system
both of the arm rests/restraint/safety malfunction.
Parking brake button until indicator
goes out. bars are up, and/or the swing-out
door (if equipped) is opened for more
Park Brake (green) on DIAGNOSTIC than 0.5 seconds, the lockout sole-
INPUTS screen (while parking brake noid is turned on, the lift/tilt and travel
button is pressed). drive is disabled, and the parking
brake is set.

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 Electrical Controls System
Ignition/Starting Functional Detail
Table 6 - Ignition/Starting Functional Detail
Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions
All indicator lights, key pad but-
ton back lights and audible alarm
activate for 3 seconds to test; test
Ignition switch in ON/RUN position. interrupted if the ignition switch is
turned to the START position.
Power On Ignition Run (green) on DIAGNOSTIC
INPUTS screen. Parking brake push button indicator
is lit.
Disable Park Brake (blank) on
DIAGNOSTIC OUTPUTS screen.
Main power off.
Ignition switch in OFF position.
Power Off
NOTE: Dome light does not
Dome light OFF.
require ignition on/run to operate.
Printed in U.S.A. 233
Malfunction Causes
Ignition switch malfunction.
Electrical fault (switch,
components, connections or
battery).
NOTE: If display and/or
keypad does not power up:
Make sure battery discon-
nect switch is in the ON
position.
Check battery terminal
connections.
Check for sufficient battery
voltage (12VDC).
Check for power to display
at pin #1 (12VDC), and/or
keypad(s).
If no power to display and/or
keypad, check fuse and also
electrical connections in the
fuse box.
Check for proper grounding
on display at pin #2, and/or
keypad(s).
Ignition switch malfunction.
Electrical fault (switch,
components, connections or
battery).
50950457/A0719
Electrical Controls System
Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions
Seat switch CLOSED (seat
occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Swing-out door (if equipped) closed. Starter (green) on DIAGNOSTIC
Restraint Bar (green) on
DIAGNOSTIC INPUTS screen.
Start Engine
Ignition switch in START position.
Ignition Start (green) on
DIAGNOSTIC INPUTS screen.
Ignition Run (green) on DIAGNOSTIC
INPUTS screen.
Alternator (green) on DIAGNOSTIC
INPUTS screen.
Stop Engine Ignition switch in OFF position.
Seat switch CLOSED (seat
occupied).
Seat Switch (green) on DIAGNOSTIC switch in the ON/RUN position if
INPUTS screen.
Ignition switch in ON/RUN position.
Fuel Pump
Activation Ignition Start (green) on
DIAGNOSTIC INPUTS screen.
Ignition Run (green) on DIAGNOSTIC if the ignition switch is held in the
INPUTS screen.
Alternator (green) on DIAGNOSTIC
INPUTS screen.
50950457/A0719
Malfunction Causes
Ignition switch malfunction.
Electrical fault (switch,
components, connections, or
OUTPUTS screen.
battery).
Turns on and holds engine start.
Starter malfunction.
NOTE: Engine start disabled if the
Component/safety interlock
ignition is in the START position for
system malfunction.
longer than 15 seconds.
CAN error/ communication
fault.
Ignition switch malfunction.
Electrical fault (switch,
components, connections or
Stops fuel flow.
battery).
Engine/component
malfunction.
Fuel pump turned on for 10 seconds
to prime fuel line.
Fuel pump is turned on when ignition
switch is turned to the START posi-
tion and remain on with the ignition
Electrical/mechanical fault
any engine oil pressure is detected, (components, connections,
or if the ignition switch is held in fuses or battery).
the START position (ignition start Continuity fault between
condition). ground and power connector
Engine ECU to fuel pump
NOTE: Fuel pump is turned off
relay.
START position (ignition start condi- Fuel pump relay malfunction.
tion) longer than 15 seconds.
NOTE: Fuel pump is also turn off it
a high engine coolant temperature or
a low engine oil pressure condition is
detected.
234 Printed in U.S.A.

Operation Functional Detail
Table 7 - Operation Functional Detail
Function Reference LEDs Inputs/Conditions
Engine is running (engine oil pressure
detected).
Throttle Speed Throttle speed analog input value is
Adjust between 0.5-4.5 VDC.
NOTE: Both hand and foot throttles are
included in throttle input.
Ignition switch in ON/RUN position.
Fuel Level
Sender Fuel level sender resistance: 31.5-34.5
ohms full; 236.5-245.7 ohms empty.
Ignition switch in ON/RUN position.
Engine Coolant
Engine coolant temperature sender resis-
Temperature
tance (ohms) determines displayed coolant
temperature.
Lift Arm Functional Detail
Table 8 - Lift Arm Functional Detail
Function Reference LEDs Inputs/Conditions
Seat switch CLOSED (seat occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Engine off lift arm Swing-out door (if equipped) closed.
lower
Restraint Bar (green) on DIAGNOSTIC
INPUTS screen.
Ignition switch in ON/RUN position.
Float control is engaged.
Printed in U.S.A.
Electrical Controls System
Reference LEDs Outputs/Actions
Throttle speed CAN message is
sent to engine ECU.
Throttle speed is set to the highest
of the two values between the hand
and foot throttles.
NOTE: If the throttle speed
analog input value is out-of-range, a NOTE: Engine-specific
CAN error code is generated.
Fuel level CAN data broadcast and or battery).
appears on the display.
Engine coolant temperature CAN
data broadcast and appears on the
display.
NOTE: Coolant Temperature
Warning Indicator lit and engine
de-rate occurs at 110°C (230° F). CAN error/communication
Engine shutoff occurs if tempera-
ture exceeds 118°C (245° F) for 30
seconds.
Reference LEDs Outputs/Actions
Float (green) on DIAGNOSTIC
OUTPUTS screen.
Lift arm lowers.
235
Malfunction Causes
Throttle control
malfunction.
Electrical fault (switch/
components/connections).
Component malfunction.
CAN error/communication
fault (outof-range).
diagnostic software may
be needed for in-depth
troubleshooting.
Electrical fault (switch,
components, connections
CAN error/communication
fault.
Electrical fault (switch,
components, connections
or battery).
fault.
Malfunction Causes
Electrical fault
(switch/components/
connections).
Component/safety inter-
lock system malfunction.
Mechanical malfunction.
50950457/A0719
Electrical Controls System
Function Reference LEDs Inputs/Conditions
Engine is running (engine oil pressure
detected).
Seat switch CLOSED (seat occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Swing-out door (if equipped) closed.
Lift arm float
Restraint Bar (green) on DIAGNOSTIC
INPUTS screen.
Parking brake pressed until indicator goes
out.
Park Brake (green) on DIAGNOSTIC
INPUTS screen (while parking brake button deactivates float. When float is on
is pressed).
Lift arm float control is engaged.
Drive System Functional Detail
Table 9 - Drive System Functional Detail
Function Reference LEDs Inputs/Conditions
Engine is running (engine oil pressure
detected).
Seat switch CLOSED (seat occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Travel Drive Swing-out door (if equipped) closed.
Activated
Restraint Bar (green) on DIAGNOSTIC
INPUTS screen.
Parking brake pressed until indicator goes
out.
Park Brake (green) on DIAGNOSTIC
INPUTS screen (while parking brake button
is pressed).
50950457/A0719
Reference LEDs Outputs/Actions Malfunction Causes
Float (green) on DIAGNOSTIC
OUTPUTS screen.
Float solenoids in hydraglide/float
valve activate lift arm float.
Electrical fault
Lift Arm Float indicator symbol on (switch/components/
the indicator panel light either is connections).
lit continuously (latched on), or
Component/safety inter-
flashes (momentary).
lock system malfunction.
NOTE: Lift arm float latches on
Mechanical malfunction.
continuously if the lift arm float
button is held for 5 seconds. When Hydraulic system/valve
float is latched on continuously, malfunction.
pressing the lift arm float button
momentarily, releasing the lift arm
float button deactivates float.
Reference LEDs Outputs/Actions Malfunction Causes
Disable Park Brake (green) on
Electrical fault
DIAGNOSTIC OUTPUTS screen.
(switch/components/
Pilot valve flow to travel motor connections).
parking brake turned off (disen-
Component/safety inter-
gages parking brake against spring
lock system malfunction.
pressure).
Hydraulic system
Travel drive control handle lockout
malfunction
valve solenoid turned off.
236 Printed in U.S.A.

Function Reference LEDs Inputs/Conditions
Engine is running (engine oil pressure
detected).
Seat switch CLOSED (seat occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Swing-out door (if equipped) closed.
Restraint Bar (green) on DIAGNOSTIC
Right-Side Travel INPUTS screen.
Drive Reverse
Parking brake pressed until indicator goes Hydraulic pressure detected by
out.
Park Brake (green) on DIAGNOSTIC
INPUTS screen (while parking brake button DIAGNOSTIC OUTPUTS screen.
is pressed).
Left control handle moved to a position to
activate right-side reverse travel.
RH Backup (green) on DIAGNOSTIC
INPUTS screen.
Engine is running (engine oil pressure
detected).
Seat switch CLOSED (seat occupied).
Seat Switch (green) on DIAGNOSTIC
INPUTS screen.
Arm rests/restraint/safety bars down.
Swing-out door (if equipped) closed.
Restraint Bar (green) on DIAGNOSTIC
Left-Side Travel INPUTS screen.
Drive Reverse
Parking brake button pressed until indicator Hydraulic pressure detected by
goes out.
Park Brake (green) on DIAGNOSTIC
INPUTS screen (while parking brake button DIAGNOSTIC OUTPUTS screen.
is pressed).
Left control handle moved to a position to
activate left-side reverse travel.
LH Backup (green) on DIAGNOSTIC
INPUTS screen.
Printed in U.S.A.
Electrical Controls System
Reference LEDs Outputs/Actions Malfunction Causes
Disable Park Brake (green) on
DIAGNOSTIC OUTPUTS screen.
Pilot valve flow to travel motor
parking brake turned off (disen-
gages parking brake against spring
pressure). Electrical fault
(switch/components/
Travel drive joystick lockout valve connections).
solenoid turned off.
Component/safety inter-
lock system malfunction.
drive pressure sensor.
Hydraulic system
Backup Alarm (green) on malfunction
NOTE: Backup alarm is acti-
vated only if hydraulic pressure is
detected on both the left and right
side at the same time.
Disable Park Brake (green) on
DIAGNOSTIC OUTPUTS screen.
Pilot valve flow to travel motor
parking brake turned off (disen-
gages parking brake against spring
pressure). Electrical fault
(switch/components/
Travel drive joystick lockout valve connections).
solenoid turned off.
Component/safety inter-
lock system malfunction.
drive pressure sensor.
Hydraulic system
Backup Alarm (green) on malfunction
NOTE: Backup alarm is acti-
vated only if hydraulic pressure is
detected on both the left and right
side at the same time.
237 50950457/A0719
Electrical Controls System
Auxiliary Hydraulics Functional Detail
Table 10 - Auxiliary Hydraulics Functional Detail

Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions Malfunction Causes

Engine is running (engine oil pressure
detected).
NOTE: Any combination of the following
DIAGNOSTIC INPUTS are possible:
Seat Switch (green) on DIAGNOSTIC Auxiliary hydraulics forward sole-
INPUTS screen. noid is turned on and the auxiliary
Auxiliary Electrical fault
hydraulics flow is activated.
Hydraulics Restraint Bar (green) on DIAGNOSTIC (components/connections).
Forward Flow INPUTS screen. NOTE: Maximum auxiliary
Hydraulic component/sys-
Activation hydraulics flow rate is base on
Park Brake (green) on DIAGNOSTIC tem malfunction.
engine speed and is attenuated by
INPUTS screen. the analog signal level.
Auxiliary hydraulics is moved to the forward
position.
NOTE: Analog signal level input in the
range of 2.55-4.5 VDC.
Engine is running (engine oil pressure
detected).
NOTE: Any combination of the following
DIAGNOSTIC INPUTS are possible:
Seat Switch (green) on DIAGNOSTIC Auxiliary hydraulics reverse sole-
INPUTS screen. noid is turned on and the auxiliary
Auxiliary Electrical fault
hydraulics flow is activated.
Hydraulics Restraint Bar (green) on DIAGNOSTIC (components/connections).
Reverse Flow INPUTS screen. Maximum auxiliary hydraulics flow
Hydraulic component/sys-
Activation rate is base on engine speed and
Park Brake (green) on DIAGNOSTIC tem malfunction.
is attenuated by the analog signal
INPUTS screen. level.
Auxiliary hydraulics control is moved to the
reverse position.
NOTE: Analog signal level input in the
range of 0-2.55 VDC.

50950457/A0719 238 Printed in U.S.A.

 Electrical Controls System

Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions Malfunction Causes

Engine is running (engine oil pressure
detected).
NOTE: Any combination of the following
DIAGNOSTIC INPUTS are possible:
Auxiliary hydraulics is latched on,
Seat Switch (green) on DIAGNOSTIC and continuous flow is activated.
INPUTS screen. NOTE: If either the auxiliary
Restraint Bar (green) on DIAGNOSTIC hydraulics control and/or the flow
INPUTS screen. latch position are moved/pressed,
Auxiliary Electrical fault
the auxiliary hydraulics solenoid(s)
Hydraulics Park Brake (green) on DIAGNOSTIC (components/connections).
are turned off and continuous flow
Continuous INPUTS screen.
stops. Hydraulic component/sys-
Flow Latching
Auxiliary hydraulics control is moved to tem malfunction.
ON (Detent) NOTE: If activated, auxiliary
either the full forward or reverse position.
hydraulics continuous flow remains
NOTE: Analog signal level input in the latched ON if the operator leaves
range of 0-2.55 (reverse) or 2.55-4.5 (for- the seat, arm rests/restraint/safety
ward) VDC. bars are lifted, or the parking brake
button is pressed.
Auxiliary hydraulics continuous flow is
toggled ON.
Aux Detent (green) on DIAGNOSTIC
INPUTS screen.

Warning Indicators Functional Detail

Table 11 - Warning Indicators Functional Detail

Function Reference LEDs Inputs/Conditions Reference LEDs Outputs/Actions Malfunction Causes

Engine is running (engine oil pressure Electrical fault
detected). (components/connections).

Hydraulic oil temperature is above approxi- IMPORTANT: High

High Hydraulic mately 110° C (230° F). Hydraulic oil high temperature indi- hydraulic oil tempera-
Temperature cator symbol on the indicator panel ture can indicate seri-
Activation Hydraulic oil high temperature sender light is lit. ous hydraulic system
switch ON. malfunction.
High hydraulic tempterature (green) on CAN error/ communication
DIAGNOSTIC INPUTS screen. fault.
Engine coolant high temperature Electrical fault(components/
indicator symbol on the indicator connections).
panel light is lit. NOTE: High engine
High Engine Engine is running (engine oil pressure
detected). NOTE: Coolant Temperature coolant temperature
Coolant
Warning Indicator lit and engine can indicate a serious
Temperature High engine temperature CAN message
de-rate occurs at 110°C (230° F). engine cooling system
Activation broadcast by engine ECU.
Engine shutoff occurs if tempera- malfunction.
ture exceeds 118°C (245° F) for 30 CAN error/ communication
seconds. fault.

Printed in U.S.A. 239 50950457/A0719

Electrical Controls System
Function Reference LEDs Inputs/Conditions
Engine is running (engine oil pressure
Low Engine detected).
Oil Pressure
Activation Low engine oil pressure CAN message
broadcast by engine ECU.
Engine is running (engine oil pressure
detected).
Check Engine
Activation Check engine CAN message (various
engine error codes) broadcast by engine
ECU.
Lighting Functional Detail
Table 12 - Lighting Functional Detail
Function Reference LEDs Inputs/Conditions
Ignition switch in ON/RUN position.
Work lights switch on the control keypad is
Optional activated, to either tail lights ON, front work
Beacon/Work lights with tail lights on, or both front and
Lights Activation rear work lights ON.
Rear Work/Tail Lts - and/or - Front Work Lts
(green) on DIAGNOSTIC OUTPUTS screen.
50950457/A0719
Reference LEDs Outputs/Actions
Low engine oil pressure indicator
symbol on the indicator panel light
is lit.
NOTE: Engine Oil Pressure
Warning and Engine Malfunction
indicators lit at 1.6 bar (23 psi).
Engine shutoff occurs if pressure
falls to 0.5-1.3 bar (7-18.6 psi).
Check engine indicator symbol
on the indicator panel light is lit
and appears on the multi-purpose
display.
NOTE: Various engine error
codes may be broadcast. May
cause engine de-rating condition.
Reference LEDs Outputs/Actions
Front Work Lts (green) on
DIAGNOSTIC OUTPUTS screen,
and Rear Work/Tail Lts (green) on
DIAGNOSTIC OUTPUTS screen.
240
Malfunction Causes
Electrical fault(components/
connections).
IMPORTANT: Low
engine oil pressure
indicates a serious engine
malfunction. Shut down
the engine immediately if
the low engine oil pressure
indicator symbol appears
on the display. Correct the
problem before running the
machine. Damage to the
engine may result if the
engine is run with low oil
pressure.
CAN error/ communication
fault.
Electrical fault
(components/connections).
NOTE: Refer to “Engine
Error Codes” on page 88.
CAN error/ communication
fault.
Malfunction Causes
Burned out bulb(s).
Ignition switch malfunction.
Electrical fault (switch,
components, connections
or battery).
Printed in U.S.A.
 Electrical Controls System

CAN/Control System Troubleshooting

Inputs/Outputs Detail
The Inputs/Output screens available on the multi-function display show feedback state of controller compo-
nents, allowing for systematic troubleshooting.

Inputs/Outputs screens are accessed by holding down the ok button on the multi-purpose display for 10
seconds while either the primary or dual gauge display screen is displayed. Press the left/right side of navi-
gation rocker button to switch to the Inputs/Outputs screens.

Press “esc” button on the multi-purpose display to exit the Input/Outputs.

Inputs Detail

DIAGNOSTIC INPUTS DIAGNOSTIC INPUTS

Float Ignition Run Park Brake
HydraGlide Ignition Start Beacon/Work Lt
High Gear Seat Switch Self Level
Aux Detent Restraint Bar Pow Tach Lock
Alternator LH Backup Pow Tach Unlock
Hyd Filter Clog RH Backup
High Hyd Temp High Flow FWD
Wiper Interlock High Flow REV

Fig. 414 - Diagnostic Inputs Screens

Table 13 - Diagnostic Inputs Screens

Item Input Description Status Condition

ON/OFF digital electrical sig- Alternator output voltage/ cur-
nal. ON when system detects rent status.
current from alternator. Alternator voltage/current
If OFF with engine running, Green
output detected
Alternator When ON, CAN “Alternator” audible alert (buzzer) in display
input message displays. activated for 5 secs.
No alternator voltage/current
Blank
output detected

High temperature hydraulic oil

signal from hydraulic system
temperature sender switch.
CAN “High Hyd Temp”
High Hydraulic
DIAGNOSTIC INPUT mes-
Temperature
sage to display.
Hydraulic oil high temperature
out-of-range CAN message
status.
Hydraulic system tempera-
ture sender switch indicates
Green
system over-temperature
condition.
No hydraulic system
Blank overtemperature condition
detected.

Printed in U.S.A. 241 50950457/A0719

Electrical Controls System
Item Input
Digital electrical engine run
signal (12VDC ON/OFF) from Ignition switch RUN position
ignition switch to display.
CAN “Ignition Run”
Ignition Run
DIAGNOSTIC INPUT mes-
sage to display.
Digital electrical start signal
(12VDC ON/OFF) from igni-
tion switch to display.
CAN “Ignition Start”
Ignition Start
DIAGNOSTIC INPUT mes-
sage to display.
ON/OFF digital electrical
signal (12VDC ON/OFF) to
safety interlock system.
ON/OFF digital electrical
signal (12VDC ON/OFF) from Seat switch (in seat cushion)
seat switch through main ON/OFF status.
Seat Switch keypad to display.
CAN “Seat Switch”
DIAGNOSTIC INPUT mes-
sage to display.
50950457/A0719
Description Status Condition
status. Ignition keyswitch IS in the
Green
“Ignition run” message broad- run or start position.
cast on CAN system.
Ignition keyswitch IS NOT in
Blank
the run or start position.
Ignition switch START position
status.
CAN “Starter” DIAGNOSTIC
OUTPUT message to display.
NOTE: Safety interlock logic
enables ignition start when
arm rests/restraint/safety bars
are down (“Restraint Bar” Ignition keyswitch IS in the
DIAGNOSTIC INPUT) and Green
start position.
seat is occupied (“Seat Switch”
DIAGNOSTIC INPUT).
CAN “Starter” DIAGNOSTIC
OUTPUT message to display.
NOTE: Ignition switch start
position is momentary, rotated
full clockwise.
Ignition keyswitch IS NOT in
Blank
the start position.
Seat switch is closed (seat
Green
IS occupied).
Seat switch is open (seat IS
Blank
NOT occupied).
242 Printed in U.S.A.
 Electrical Controls System

Item Input Description Status Condition

Digital electrical restraint bar
signal (12VDC ON/OFF) from
restraint bar/arm rest switch to
display.
Green only when restraint Restraint bar down (switch
Digital electrical restraint bar switch is closed, and (if closed).
bar signal (12VDC ON/OFF) equipped) additionally optional Green
from swing-out door switch (if swing-out door (if equipped) If equipped, swing-out door
equipped) to display. switch closed. closed (switch closed)

Restraint Bar CAN “Restraint Bar”

DIAGNOSTIC INPUT mes-
sage to display
NOTE: Any combination of
the following:
Restraint bar IS NOT down
Blank
(switch open).
If equipped, swing-out door
open (switch open).

Left-side reverse travel is

Digital electrical LH backup
signal (12VDC ON/OFF) from
left-side track reverse circuit
pressure switch to display.
CAN “LH Backup”
Left Backup
DIAGNOSTIC INPUT mes-
sage to display.
activated.
NOTE: Both LH Backup and
Left-side track reverse circuit
RH Backup must be (green)
Green pressure switch is ON/
for CAN Backup Alarm output
message (“Backup Alarm” CLOSED.
DIAGNOSTIC OUTPUT) to be
generated and backup alarm
speaker to be activated.
Left-side track reverse circuit
Blank pressure switch is OFF/
OPEN.

Right-side reverse travel is

Digital electrical RH backup
signal (12VDC ON/OFF) from
right-side track reverse circuit
pressure switch to display
CAN “RH Backup”
Right Backup
DIAGNOSTIC INPUT mes-
sage to display.
activated.
NOTE: Both RH Backup and
Right-side track reverse
LH Backup must be (green) for
Green circuit pressure switch is ON/
CAN Backup Alarm message
(“Backup Alarm” DIAGNOSTIC CLOSED.
OUTPUT) to be generated and
backup alarm speaker to be
activated.
Right-side track reverse
Blank circuit pressure switch is
OFF/OPEN.

Printed in U.S.A. 243 50950457/A0719

Electrical Controls System

Item Input Description Status Condition

Momentary parking brake
switch closed/open (pressed/not
pressed) status.
NOTE: If the operator’s seat
is occupied, the armrests are
down, and the optional swing-
Parking brake switch is out door (if installed) is closed, Parking brake switch is
pressed. pressing the parking brake pressed.
CAN “Park Brake” switch for several seconds dis-
DIAGNOSTIC INPUT mes- engages parking brake (parking Green Park Brake (green) on
Park Brake DIAGNOSTIC INPUTS
sage to display (while parking brake switch light goes out).
screen.
brake switch is pressed). Any combination of pressing
the parking brake switch again,
leaving the operator’s seat,
lifting armrests, or opening
the optional swing-out door (if
installed) will engage the parking
brake.
Parking brake switch is not
Blank
pressed.

50950457/A0719 244 Printed in U.S.A.

 Electrical Controls System
Outputs Detail

DIAGNOSTIC OUTPUTS DIAGNOSTIC OUTPUTS

High Gear Float Front Wiper
Self Level Backup Alarm Front Washer
Hydraglide High Flow Rev Rear Wiper
Rear Work Lts High Flow Fwd Rear Washer
Front Work Lts Beacon Lts Blower Low
Starter Disable Park Brake Blower Med
All Tach Lock Blower High
All Tack Unlock Condenser Fan

Fig. 415 - Diagnostic Outputs Screens

Table 14 - Diagnostic Outputs Screens

Item Input Description Status Condition

CAN “Starter” DIAGNOSTIC
OUTPUT message to display.
Digital electrical start signal
(12VDC ON/OFF) to ECU.
NOTE: Start signal is sent
only if safety interlock con-
ditions are met: Arm rests/
restraint/safety bars are down
(“Restraint Bar” DIAGNOSTIC
INPUT) and seat is occupied
Starter (“Seat Switch” DIAGNOSTIC
INPUT).
Engine start signal ON/OFF
status.
Results from ignition switch
moving to the start position, with Ignition keyswitch IS in
safety interlock conditions met. the start position and
safety interlock conditions
NOTE: Ignition switch start Green are met.
position is momentary, rotated
full clockwise. “Starter” CAN message is
broadcast.
CAN “Ignition Start”
DIAGNOSTIC INPUT message
to display.
Ignition keyswitch IS NOT
in the start position and/or
safety interlock conditions
Blank are NOT met.
“Starter” CAN message is
not broadcast.
Short circuit between
Red
starter and ECU.
Yellow Open circuit.

Printed in U.S.A. 245 50950457/A0719

Electrical Controls System

Item Input Description Status Condition

Backup alarm activation status.
Results from digital electrical LH
and RH backup signals (12VDC
ON/OFF) from left and right-side
track reverse circuit pressure
switches to display. Travel drive on both left
CAN “LH Backup input mes-
CAN “LH Backup” DIAGNOSTIC and right sides is operat-
sage to display.
INPUTmessage to display. Green ing in reverse.
CAN “RH Backup” input mes-
CAN “LH Backup” DIAGNOSTIC Backup alarm is
sage to display.
INPUT message to display. activated.
NOTE: Both LH Backup and
Backup Alarm
RH Backup must be (green) for
CAN Backup Alarm message to
be generated and backup alarm
speaker to be activated.
Travel drive on either
left or right side is NOT
Blank operating in reverse.
Backup alarm is
deactivated.
Short circuit between
Red
ECU and backup alarm.
Yellow Open circuit.

Parking brake engage/released

status.
Results from ON/OFF signal
CAN “Disable Park Brake”
from parking brake switch to
DIAGNOSTIC OUTPUT mes-
display.
sage to display.
CAN “Park Brake” DIAGNOSTIC Green Parking brake is released
ON/OFF digital electrical signal (OFF).
INPUT message to display
(12VDC ON/OFF) to park brake
Disable Park (while parking brake switch is
(pilot) valve solenoid /drive
Brake pressed).
supply valve solenoid.
ON/OFF digital electrical signal
(12VDC ON/OFF) to backlight in
parking brake switch.
Parking brake is engaged
Blank
(ON).
Red Short circuit.
Yellow Open circuit.

50950457/A0719 246 Printed in U.S.A.


Indicator Lamp Troubleshooting
Table 15 - Indicator Lamp Troubleshooting
Indicator Icon Indicator Description
Engine Error Indicator
Engine Oil Pressure
Hydraulic Oil Temperature
Coolant Temperature
Battery Voltage
Glow Indicator
Printed in U.S.A. 247
Electrical Controls System
Possible Cause
The engine Electronic Control
Unit (ECU) has detected an
error condition.
Engine oil pressure too low.
Engine oil level incorrect.
Oil Pump malfunction.
Hydraulic oil temperature too
hot.
Drive system continuously
overloaded.
Lift/tilt or auxiliary system
continuously overloaded.
Drive motor(s) or hydrostatic
pump(s) internal damage/
leakage.
Oil cooler fins restricted.
Hydraulic oil filter restricted.
Coolant level too low.
Air filter plugged.
Coolant leak.
Alternator not charging
properly.
Faulty crank sensor
Corrective Action
Refer to engine diagnostic
codes.
Stop engine immediately.
Check oil level and add oil if
necessary.
Adjust oil level.
Contact dealer.
Check cooling system. Check
hydraulic oil level.
Check hydraulic oil level.
Improve operation procedure.
Improve operation procedure.
Contact dealer.
Clean oil cooler fins.
Replace filter.
Add coolant.
Replace air filter.
Repair cooling system and top-
off coolant.
Adjust belt tension.
Repair/replace alternator.
Refer to engine diagnostic
codes.
50950457/A0719


50950457/A0719 248 Printed in U.S.A.

 Chapter 10
ELECTRICAL SYSTEM
Introduction

Description of Operation - Instrument

Inspect and check the electrical system at Panel - DPF Models
regular intervals. Defects, such as loose con-
nections or scorched cables must be repaired 1
before using the machine.
Only use proper, original equipment fuses
with the specified current rating. Turn off the
machine immediately if there is any indication 2
of a problem with the electrical system.
Disconnect the negative battery cables from the
negative battery terminals, before performing
electrical service or electrical welding on the
machine.
Turn off all electrical equipment before connect- 3
ing leads to the batteries, including electrical
switches on the battery charger or jump-start-
ing equipment. 8 4

When disconnecting at the battery terminals, 5

remove the cable connected to the negative 9
terminal first. When installing a battery, connect 6
the positive terminal cable first. 10
7
Sparks and open flames can ignite explosive
battery gas from incidental contact or static
discharge. Turn off all switches and the engine
when working on batteries. Keep battery termi- 11
nals tight. Contact between a loose cable clamp
and a terminal post can create an explosive
spark. 12
Work on the electrical system must be per-
formed only by a trained technician.

13

14
Battery
Refer to “Battery” on page 66 for detailed battery
maintenance information.

Fig. 416 - Instrument Panel - DPF Models

The instrument panel for DPF model track loaders

includes a parking brake switch, engine preheat

Printed in U.S.A. 249 50950457/A0719

Electrical System
switch, light switch, 12-VDC power outlet and
keyswitch.
The instrument panel contains the following
switches and indicators. Symbols on the panel
represent various functions and conditions, and are
visible only when indicator lamps are on.
1. Keyswitch – In a clockwise rotation, these posi-
tions are:
• OFF Position – With the key vertical, power
from the battery is disconnected from the con-
trols and instrument panel electrical circuits.
This is the only position from which the key can
be inserted or removed.
• ON (or RUN) Position – With the key turned
one position clockwise from vertical, power
from the battery is supplied to all control and
instrument panel circuits.
• START Position – With the key turned fully
clockwise, the electric starter engages, to start
the engine. Release the key to RUN position
after the engine starts.
NOTE: The engine cannot be started unless the
operator is sitting in the seat and the restraint bar
is lowered. To verify that the seat and restraint bar
switches are working properly, after the keyswitch
is turned to ON, raise the restraint bar or lift body
off the seat. Either action should prevent the engine
from cranking with the keyswitch turned to START.
2. Information Center Electronic Display.
3. Fuel Level Gauge – Displays the amount of fuel
in the tank.
4. Fasten Seatbelt – A momentary visual (and audi-
ble) indicator to remind the operator to fasten
the seatbelt.
5. Engine Oil Pressure – Lights if the engine oil
pressure drops too low, warning the operator
to immediately stop the engine and determine
the cause for the pressure drop. During normal
operation, this indicator should be OFF
6. Battery – Lights if the charging voltage is too
high or too low. During normal operation, this
indicator should be OFF.
50950457/A0719
7. Preheat Indicator Lamp – Lights when the
(automatic) preheat is active. During normal
operation this indicator should be OFF.
8. Engine Malfunction Lamp – Indicates the
engine ECU has detected a malfunction of the
engine.
9. Engine Coolant Temperature – Lights if the
engine coolant becomes too hot, warning the
operator to stop the engine. Allow the engine to
cool, determine the cause for the high tempera-
ture and correct the problem before restarting
the engine. During normal operation, this indi-
cator should be OFF.
10. Hydraulic Oil Temperature – Lights if the
hydraulic oil becomes too hot, warning the
operator to stop engine. Allow the hydraulic
system to cool and determine the cause of the
high temperature. During normal operation, this
indicator should be OFF.
11. Parking Brake Switch – Used to manually apply
the parking brake. Lights when the parking
brake is applied.
12. Engine Speed Control – Controls the engine
speed. Move the control clockwise to increase
and counter-clockwise to decrease the engine
speed.
13. Light Switch – Controls all the lights on the
loader. Symbols denote the four positions of the
light switch. In a clockwise direction these are:
• OFF
• Front Work Lights with Tail Lights ON
• both Front and Rear Work Lights
• For the lights to function, the keyswitch must be
in the RUN position.
14. Accessory Outlet – 12-volt DC power outlet.
250 Printed in U.S.A.

Description of Operation - Instrument
Panel - Non-DPF Models
Electrical System
The instrument panel contains the following
switches and indicators. Symbols on the panel
represent various functions and conditions, and are
visible only when indicator lamps are on.

1. Hourmeter – Displays the total operating hours

10
on the loader.
1
2. Fuel Level Gauge – Displays the amount of fuel
in the tank.
3. Engine Coolant Temperature Gauge – Indicates
2
the engine coolant temperature.
NOTE: Items 4 through 9 are indicator lamps
3 which display the following:
4. Fasten Seatbelt – A momentary visual (and audi-
ble) indicator to remind the operator to fasten
the seatbelt.
4
5. Engine Oil Pressure – Lights if the engine oil
8 5 pressure drops too low, warning the operator
to immediately stop the engine and determine
6 the cause for the pressure drop. During normal
9 operation, this indicator should be OFF.
7
6. Battery – Lights if the charging voltage is too
high or too low. During normal operation, this
indicator should be OFF.
11 7. Preheat Indicator Lamp – Lights when the pre-
heat switch is pressed. During normal operation,
this indicator should be OFF.

12 8. Engine Coolant Temperature – Lights if the

13
14
Fig. 417 - Instrument Panel - Non-DPF Models
The instrument panel for Non-DPF model track
loaders includes a parking brake switch, engine
preheat switch, light switch, 12-VDC power outlet
and keyswitch.
Printed in U.S.A.
engine coolant becomes too hot, warning the
operator to stop the engine. Allow the engine to
cool, determine the cause for the high tempera-
ture and correct the problem before restarting
the engine. During normal operation, this indi-
cator should be OFF.
9. Hydraulic Oil Temperature – Lights if the
hydraulic oil becomes too hot, warning the
operator to stop engine. Allow the hydraulic
system to cool and determine the cause of the
high temperature. During normal operation, this
indicator should be OFF.
10. Keyswitch – In a clockwise rotation, these posi-
tions are:
• OFF Position – With the key vertical, power
from the battery is disconnected to the controls
251 50950457/A0719
Electrical System
and instrument panel electrical circuits. This
is the only position the key can be inserted or
removed from the keyswitch.
• ON (or Run) Position – With the key turned one
position clockwise from vertical, power from
the battery is supplied to all control and instru-
ment panel electrical circuits.
• START Position – With the key turned fully
clockwise, the electric starter energizes, start
the engine. Release the key to the RUN position
after the engine starts.
NOTE: The engine cannot be started unless the
operator is sitting in the seat and the restraint bar
is lowered. To verify that the seat and restraint bar
switches are working properly, after the keyswitch
is turned to ON, raise the restraint bar or lift body
off the seat. Either action should prevent the engine
from cranking with the keyswitch turned to START.
11. Parking Brake Switch – Used to manually apply
the parking brake. The red indicator on the
switch lights when the parking brake is applied.
12. Light Switch – Controls all the lights on the
loader. Symbols denote the four positions of the
light switch. In a clockwise direction these are:
• OFF
• Tail Lights ON
• Front Work Lights with Tail Lights ON
• both Front and Rear Work Lights
• For the lights to function, the keyswitch must be
in the RUN position.
13. Circuit Breakers – Four circuit breakers on the
instrument panel protect the loader’s electrical
circuits.
IMPORTANT: Do not attempt to defeat the circuit
protection by jumping across a circuit breaker or by
using a higher amperage circuit breaker.
14. Accessory Outlet – 12-volt DC power outlet.

50950457/A0719 252 Printed in U.S.A.

 Electrical System

Components

ROPS/FOPS Instrument Panel - DPF Models

7 Housing/Display 16 Switch/Ignition 32 LW #10 RZY

8 Bulb/Lamp 17 Screw Mach Phil Truss Hd 1/4-20-3/4 33 HN MS #1024 CZY
9 Gasket/Display Housing 19 Switch/Brake Momentary 34 Screw/THM CR 1/4x1/2 C2ZY
11 Gauge/Fuel Level 22 Panel/Instrument/Assy 50 Fastening Ring
12 Connector/12v Power Port 24 Display/Programmed 60 KEY/8001 (14603)
13 Cover/12v Power Port 26 Decal/Instrument Panel 61 Key Cover/Rubber/8001 (14603)
Fig.
14 418
Light-Switch
ROPS/FOPS Instrument Panel Components - DPF Models
29 Throttle
15 Knob/Control Skirted 30 BHSCS #1032x3/4 C8 OCG

Printed in U.S.A. 253 50950457/A0719

Electrical System
ROPS/FOPS Wire Harness Group Components - DPF Models

1 Tie/Cable .19 x 7.50 Black 20 Modual/Control Interlock 33 HN MS #1024 CZY

2 Clamp/Hose 1.12 x .41 Hole 21 Knob/Clamping .31 nut 35 BHSCS 5/16x3/4 C8 OCB
3 HLN INST 5/16 CZY 23 Harness/Rops 36 HWHTRS Tap/R 5/16x3/4 CZY
4 CS FL LOCK 5/16x1 C5ZY 25 Mount/Cover/Wldmnt 40 LN FL SERR 1/4 CZY
5 Nut/Speed 27 Cover/Electrical Harness 41 LN FL SERR 5/16 CZY
10 Clamp/Hose .75 x .41 Hole 28 Cover Assy/Electrical 70 Shield/Assembly
18 Mount, Wire Tie 31 BHSCS M6-1.00x16 C12.9 OCB

Fig. 419 - ROPS/FOPS Wire Harness Group Components - DPF Models

50950457/A0719 254 Printed in U.S.A.

 Electrical System
ROPS/FOPS Instrument Panel - Non-DPF Models

7 Gauge/Hourmeter 15 Cover/12v Power Port 25 Circuit Breaker 8 Amps

8 Housing/Display 16 Breaker/Circuit 15 Amp 27 Switch/Brake Momentary
9 Bulb/Lamp 17 Breaker/Circuit 25 Amp 30 Panel/Instrument/Assembly
10 Gasket/Display Housing 18 Light Switch 31 Decal/Instrument Panel
12 Gauge/Water Temp 19 Knob/Control Skirted 36 HN MS #1024 CZY
13 Gauge/Fuel Level 22 6 - 32 x 3/4 Standoff 1/4 OD 60 KEY/8001 (14603)
14 Connector/12v Power Port 24 Switch/Ignition 61 Key Cover/Rubber/8001 (14603)

Fig. 420 - ROPS/FOPS Instrument Panel Components - Non-DPF Models

Printed in U.S.A. 255 50950457/A0719

Electrical System
ROPS Wire Harness Group - Non-DPF Models

1 Tie/Cable .19 x 7.50 Black 20 LN FL SERR 1/4 CZY 33 Mount/Cover Assy

2 Clamp/Hose 1.12 x .41 Hole 21 LN FL SERR 5/16 CZY 34 Cover Assy/Electrical
3 HLN INST 5/16 CZY 23 Relay/40 AMP/Sealed 36 HN MS #1024 CZY
4 CS FL LOCK 5/16x1 C5ZY 26 Mount, Wire Tie 37 Screw/THM CR 1/4x1/2 C2ZY
5 Nut/Speed 28 Modual/Control Interlock 38 BHSCS 5/16x3/4 C8 OCB
6 LN LG FL SERR 1/4 CZ 29 Knob/Clamping .31 nut 39 HWHTRS Tap/R 5/16x3/4 CZY
11 Clamp/Hose .75 x .41 Hole 32 Wire Harness/Rops 70 Shield/Assembly

Fig. 421 - ROPS Wire Harness Group Components - Non-DPF Models

50950457/A0719 256 Printed in U.S.A.

 Electrical System
Chassis Harness - DPF Models

2 Tie/Cable .19 x 7.50 Black 74 Fuse/60 Amp 82 Fuse/ATM/10 Amp

3 Clamp/Hose .50 x .41 Hole 75 Relay/ SPST-NO 12 VDC 83 Relay SPDT 12VDC ISO 240
14 Harnesss/Chassis 76 Relay/20Amp/ISO 280 84 Fuse/60 Amp
50 Cover/Fuse-Relay 77 Fuse/ATM/10 Amp 85 Relay/ SPST-NO 12 VDC
70 Fuse/60 Amp 78 Fuse/ATM/20 Amp 86 Relay/20Amp/ISO 280
71 Fuse/ATM/15 Amp 79 Fuse/ATM/20 Amp 87 Fuse/ATM/15 Amp
72 Fuse/ATM/10 Amp 80 Fuse/60 Amp 88 Fuse/ATM/15 Amp
73 Relay/20Amp/ISO 280 81 Fuse/ATM/5 Amp

Fig. 422 - Chassis Harness Components - DPF Models

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Electrical System
Chassis Harness - Non-DPF Models

3 Tie/Cable .19 x 7.50 Black 16 Solenoid 30 CB 1/4x5/8 C5ZY

5 LN LG FL SERR 3/8 CZ 17 Relay Mounting Brkt Assy 31 HWHTRS Tap/R #1032x1/2 CZY
6 HLN INST 1/4 CZY 18 Cover/Electrical 32 HJN 5/16 C2ZY
8 Fuel Sender Gasket 19 LN FL SERR 5/16 CZY 33 LW 1/4 RZY
10 CS FL LOCK 3/8x1 C5ZY 20 Relay Mount Cover Assy 35 CS M8-1.25x14 C8.8 ZY DIN933
11 HLN INST #1024 CZY 21 Relay/40 AMP/Sealed 81 LN FL SERR 1/4 CZY
12 Sender, Fuel 24 Circuit Breaker 35amp 82 Bracket/Switch
13 LN FL SPIRALOCK 1/4 CZY 26 Wire Harness/Chassis 83 CS 1/4x5/8 C5ZY
14 Clamp/Hose .75 x .41 Hole 28 FW 3/16 AZY 84 FW 1/4 ANZY
15 Module/Auto-Glow Control 29 CB 5/16x3/4 C5ZY 90 Switch/Track Tension

Fig. 423 - Chassis Harness Components - Non-DPF Models

50950457/A0719 258 Printed in U.S.A.

 Electrical System
Battery Group and ECU - DPF Models

1 Stop, Battery Holddown 16 Mount/Fuse Box 28 CB 1/4x3/4 C5ZY

4 HLN INST 3/8 CZY 17 Mount/Ecu 29 FW 5/16 ANZY
5 HLN INST 1/4 CZY 18 Cable/Battery/Pos/17” 30 CS FL M10-1.50x20 8.8 ZY DIN6921
6 LN 5/16 CBZY 19 Cable/Alternator 31 HJN 5/16 C2ZY
7 CS FL LOCK 5/16x5/8 C5ZY 20 Cable/Battery/Neg/22” 32 LW 1/4 RZY
8 CS FL LOCK 3/8x3/4 C5ZY 21 Isolator/ 1.00”x 1.00” Neoprene 33 CS M6-1X12 C8.8 ZY DIN9333
9 Solenoid 22 Lead Wire/Starter 34 Strap Grnd 4 Ga X 14inch Silver
10 Cover/Electrical 23 CB 3/8x8-1/2 C2ZY 50 Switch/Track Tension
11 LN FL SERR 1/4 CZY 24 CS 1/4x1/2 C5ZY 60 ECU
12 Clamp, Battery 25 FW 3/16 AZY 61 Relay/20amp/Yanmar
13 Battery/12 VDC GRP 34 26 CB 5/16x3/4 C5ZY
15 Mount/Electrical/Assy 27 CB 3/8x1 C5ZY

Fig. 424 - Battery Group and ECU Components - DPF Models

Printed in U.S.A. 259 50950457/A0719

Electrical System
Battery Group - Non-DPF Models

1 Stop, Battery Holddown 9 Cable/Battery 27 CB 3/8x8-1/2 C2ZY

2 Cable/Battery 22 Clamp, Battery 29 CB 5/16x3/4 C5ZY
4 HLN INST 3/8 CZY 23 Cable, Battery, Positive 34 LW ExT T 3/8 AZY
7 LN 5/16 CBZY 25 Battery/12 VDC GRP 34

Fig. 425 - Battery Group Components - Non-DPF Models

50950457/A0719 260 Printed in U.S.A.

 Electrical System
Battery Disconnect

1 Plate/Face 4 Bracket/Battery Switch Mount 6 Nut

2 Boot/Terminal-Battery Disconnect 5 Cable/Battery/Neg/18” 20 CS FL LOCK 3/8x1/2 C2ZY
3 Switch/Disconnect/Dpole 5 Cable/Battery

Fig. 426 - Battery Disconnect Components

Printed in U.S.A. 261 50950457/A0719

Electrical System
Lights

1 Tie/Cable .19 x 7.50 Black 6 Harness/Rear Lights 11 Housing, Connector Female

2 Clamp/Hose .50 x .41 Hole 7 Grommet .69ID .188GW 1.00GD 12 Head Lamp/Oval
3 HLN INST 5/16 CZY 8 Light/Red 20 Bulb
4 Clip/Single 9 Light/Work 21 Bulb
5 Clip/Double 10 Secondary Lock

Fig. 427 - Lights Components

50950457/A0719 262 Printed in U.S.A.


Power Distribution
The electrical circuitry is protected from overload-
ing and short circuits by a combination of fuses
and relays that are contained in the power distribu-
tion modules located in the engine and operator’s
compartments. The Power Distribution Modules
(PDM’s) in the engine compartment (A, Fig. 428)
are positioned on the right side of the machine
besides the fuel tank. These modules contain fuses
and power relays that protect those circuits which
utilize live power from the battery. The power
relays function to provide key-switched power to
the circuits located in the forward PDM’s in the
operator’s compartment. The outer surface of the
cover of each PDM bears a decal that identifies the
fuses and relays contained in that module.
A BEFORE beginning this service procedure, shut
Fig. 428 - Engine Area Power Distribution Modules
The PDM located in the operator’s compartment (B,
Fig. 429) is located behind the steel access cover on
the right side of the cab at the operator’s elbow and
contains circuit-specific fuses and relays for basic
machine functions.
The ROPS/FOPS PDM contains fuses for the
instrument panel functions, headlights and safety
interlock functions. A decal on the metal access
cover identifies the fuses.
Printed in U.S.A.
Electrical System
B
Fig. 429 - ROPS/FOPS Power Distribution Module
Refer to “Fuses and Relays” on page 66 for fuse,
relay and diode location and circuit rating and func-
tion information.
Power Distribution Module Fuse Socket
Test
•
down the machine according to “Mandatory
Safety Shutdown Procedure” on page 16.
Fuses can be checked by removing them and
inspecting the internal metal link. If the link is sepa-
rated, replace the fuse.
Fuses may also be testing using a volt/ohm multi-
meter or a test lamp, measure between test points
and the chassis ground for 12V, with the wiring
connected and power applied to the selected circuit.
When the circuit is energized, 12V should be pres-
ent on both sides of the fuse.
The following procedure can be used to test the
fuses found inside the engine and ROPS/FOPS
PDM’s.
263 50950457/A0719
Electrical System
1. The ROPS/FOPS PDM (C, Fig. 430) contains
fuses and relays for the instrument panel func-
tions, headlights and safety interlock functions.
A decal on the metal access cover identifies the
fuses.
Fig. 430 - Fuses and Power Relays shown in
ROPS/FOPS PDM
Fig. 431 - Decal on ROPS/FOPS PDM fuse and
relay cover
50950457/A0719
2. The PDM’s in the engine compartment (Fig.
432, Fig. 433) contain fuses and relays that
protect the main power relays, engine operation
circuits and rear lights.
Fig. 432 - First engine PDM
Fig. 433 - Second engine PDM
3. Larger 60 amp fuses: Check for continuity
between test points with the circuits turned
“OFF”.
Control Modules and Connectors
The electrical control modules monitor and con-
trol several vital functions of the machine. Refer
to “Control Modules” on page 228 for more
information.
264 Printed in U.S.A.
 Electrical System

Component Tests 2. While the keyswitch is in the “ON” position,

test each relay individually, pull one relay out
of the panel at a time, listening for the audible
Power Relay Testing “click” of the relay opening.
3. Plug the relay back into the panel and listen for
the audible “click” of the relay re-closing, if the
#86 circuit is activated.
4. Replace any relay for which there is no discern-
#30 #87 ible “clicking” sound heard at keyed power or
opening (removing) of the relay.
#85 • The solenoid lock relay and start safety relay
will actuate only with the keyswitch in the
“ON” position, the restraint bar down and an
assistant in the seat.
Fig. 434 - Power relay terminals shown 5. Replace any relay that does not have continuity
between powered terminals #85 and #86.

Bench Test
#86 #87
1. A relay may be tested by removing it and taking
it to a work bench. Apply a ground to terminal
#87a #85 and a 12 V source to terminal #86. The
relay should actuate. There should be continuity
#30 #85 between terminal #30 and terminal #87.
2. Replace any relay that does not have continuity
between powered terminals.

Fig. 435 - Another type of power relay terminals

shown

There are two power relays inside the engine com-

partment PDM’s that supply power to the fuses for
individual circuits. The cover identifies the relays.

There are several other relays in the ROPS/FOPS

and engine compartment PDM’s that supply power
for other circuits. The covers have a decal or is
information is etched into the cover to identify the
relays.

Machine Test
1. With an operator in the seat and the restraint
bar lowered, turning the keyswitch to the “ON”
position should produce an audible “click” from
each relay closing.

Printed in U.S.A. 265 50950457/A0719

Electrical System
Starter and Glow Relay Solenoid Test -
Both DPF and Non-DPF Models
The following procedure can be used to test the
engine starter and glow solenoids. They are located
in the engine compartment on a panel on the right
chassis riser. The bottom solenoid (D, Fig. 436) is
used for the engine starter and the top solenoid (E,
Fig. 436) is used for the engine glow circuit.
E the solenoid:
D be 12 VDC only on top left large copper stud of
Fig. 436 - Location of Starter and Glow Relay
Solenoids
#86
#85
Live
Power
Load
Fig. 437 - Illustration of the Solenoids terminals.
BEFORE beginning this service procedure, per-
form the following SAFETY procedure:
• Shut off the engine.
• Raise engine cover, lock open the rear
grille.
(For detailed instructions, refer to the Safety
chapter of this manual.)
50950457/A0719
1. Remove two protective electrical covers from
the solenoids.
2. Using a volt/ohm multimeter or test lamp,
confirm the following condition with the wiring
connected.
• With keyswitch in “OFF” position, there should
be 12 VDC only on the top left large copper stud
of each solenoid.
3. The top solenoid, the engine glow circuit will
engage for a time, dependent on what the ambi-
ent temperature is. For DPF model loaders, the
engine’s ECU provides the control current for
• With keyswitch in “OFF” position, there should
the solenoid.
• Unplug the control current connector and install
a test lamp between #85 and #86 in the connec-
tor. Have a second operator turn the keyswitch
to “ON” position, the test lamp should light if
ambient temperature is low enough.
4. For engine starter solenoid:
• With keyswitch in “OFF” position, there should
be 12 VDC only on top left large copper stud of
the solenoid.
• The external starter solenoid will engine when
the keyswitch output calls for START.
• Unplug the control current connector and install
a test lamp between #85 and #86 in the connec-
tor. Have an second operator turn the keyswitch
to crank and the test lamp should light.
266 Printed in U.S.A.

Relay Test and Operation - Non-DPF
Models
Non-DPF model track loaders utilize relays in the
electrical system to maximize the efficiency of
engine, hydraulic, power and electrical operations.
Following in this section are test and operation
procedures for relays located behind a metal cover
at the operator’s right elbow (F, Fig. 438).
Electrical System
Light Bulb Replacement
Work Light Bulb Replacement
• Shut off the engine.
• Raise engine cover; lock open the rear door.
BEFORE beginning this service procedure, shut
down the machine according to “Mandatory
Safety Shutdown Procedure” on page 16.

NOTE: The front work lights are located at the top

front corners of the ROPS/FOPS. The rear work
lights can be accessed from inside the rear door.

F IMPORTANT: Do not touch new halogen bulbs

with bare fingers. Oils from skin can etch the bulb
glass and cause the bulb to fail prematurely. Wear
Fig. 438 - Non-DPF relays located in the cab
clean gloves or use a clean rag to handle new
bulbs.
1. There should be 12-VDC on terminal #87 1. Loosen the work light mount screw (G, Fig.
(#2 red wire from battery supply) at all times. 440) and turn the light down. Detach the electri-
Pushing horn button on left control handle cal connector.
should provide 12-VDC to terminal #86 and
produce an audible “click” from relay. There
should be 12-VDC on terminal #30 while horn
button is pressed.
2. Relay coil test: Using a volt/ohm multime-
ter with all wires disconnected, measure the
resistance across terminals #85 and #86. There
should be 75 ohms ± 5 ohms. There should be
no continuity between terminals #30 and #87. G

87

Fig. 440 - Screw securing lamp to the cab

87a 2. Twist the lamp base (H, Fig. 441) counterclock-

wise and remove bulb. If needed, replace bulb
86 85 with the same wattage rate H3 bulb as GE862.

30

Fig. 439 - Relay terminals shown

Printed in U.S.A. 267 50950457/A0719

Electrical System
Dome Light Bulb Replacement

• Shut off the engine.

BEFORE beginning this service procedure, shut
down the machine according to “Mandatory
H
Safety Shutdown Procedure” on page 16.

1. Climb into the cab and find dome light assembly

Fig. 441 - Bulb removed from lamp base (K, Fig. 444) on the left front stanchion of the
cab.

Tail Light Bulb Replacement

1. Release the bulb retaining clip (I, Fig. 442) and K
remove the bulb.

Fig. 444 - Dome Light Bulb shown

I
2. Find the notches and pop the dome light lens
cover out of the recessed base with a flat-tipped
screwdriver.
Fig. 442 - Bulb retaining clip shown
3. Replace the used bulb with a new GE168 bulb.
2. Replace the used bulb (J, Fig. 443) with a new
55 W H3 bulb (if a white work light), or a new
35 W H3 bulb (for red warning light).

Fig. 443 - Bulb shown outside lamp base

50950457/A0719 268 Printed in U.S.A.

 Chapter 11
CAB

Control Locations Hand/Foot Controls

On machines with “Hand/Foot Controls”, the
T-Bar Controls left and right drive control handles operate inde-
pendently of each other. With both control handles
On machines with “T-Bar Controls,” the left T-Bar
pushed forward together, the loader moves for-
operates the drive motors and pumps for both sides
ward, but push either one farther forward than the
of the machine The right T-Bar controls the lift and
other and the loader turns. Separate foot pedals
tilt functions of the lift arm and bucket. Engine
control the lift and tilt functions of the lift arm and
speed is controlled by the hand and/or foot throt-
bucket. Engine speed is controlled by the hand and/
tles, depending on a DPF or Non-DPF equipped
or foot throttles, depending on a DPF or Non-DPF
machine. Standard-flow auxiliary hydraulics is
equipped machine. The auxiliary hydraulics are
controlled by a foot pedal.
actuated by the right control handle.

3
3 6
1
6

2
4 1

1 5 2 4

Fig. 445 - DPF Model T-Bar controls

Fig. 446 - Non-DPF Model Hand/Foot controls
Ref Number Description
1 Drive Control
2 Lift/Tilt Control
3 Horn Button Switch
4 Auxiliary Hydraulics
5 Foot Throttle
6 Hand Throttle Handle

Printed in U.S.A. 269 50950457/A0719

Cab

Components

Cab (1 of 2)

1 Screw/Shoulder 1/2x2-1/2 C8 13 ROPS Support Weldment 28 Window Rear, ROPS

2 Screw/Shoulder 5/8x1 8ZY 14 ROPS Latch Weldment 30 Top Window, ROPS
3 Screw/Shoulder 1/2x1-1/4 8ZY 14 ROPS Latch Weldment 31 Strip/Locking
4 Bushing, Oilite, Flanged 16 Bushing 32 Seal/Window
8 HLN INST 5/8 CZY 17 Tag/Rip Cord 40 HJLN 1/2 C2Z
9 LN LG FL SERR 1/4 CZ 18 Ring 42 CS 1/4x3/4 C5ZY
10 LN 5/16 CBZY 19 Gas Spring, ROPS 43 CS 5/8x5-1/2 C5ZY
11 LN CTR 3/8 CBZY 21 ROPS Weldment 45 CS 5/16x1-1/2 C5ZY
12 Isolator/ROPS Mtg 22 Screw Truss Hd 1/4-20-3/4 48 FW 1/4 AWZY
13 ROPS Support Weldment 26 Spring, Extension 49 FW 5/8 AWZY

Fig. 447 - Cab components (1 of 2)

50950457/A0719 270 Printed in U.S.A.

 Cab
Cab (2 of 2)

5 FW 17/32 ZY 24 Cover Heater Access

6 Mounting/Isolation 25 Cover, Seat Plate
7 Nut/Speed 27 FW 17/32 ZY
9 LN LG FL SERR 1/4 CZ 33 Shield/Assembly
15 Plate, Upright Support 41 Screw/THWH TC USL 1/4x1/2 CZY
20 LN FL CTR 1/2 CGZY 44 CS 1/4x1/2 C5ZY
22 Screw Mach Phil Truss Hd 1/4-20-3/4 46 CS 1/2x2-3/4 C5ZY
23 Instrument Panel, Lh 47 Screw/THM CR 1/4x1/2 C2ZY

Fig. 448 - Cab Components (2 of 2)

Printed in U.S.A. 271 50950457/A0719

Cab
Interior Trim and Headliner

29 Sponge Rubber, Seat Plate

34 Foam/Rops/Rear Panel
35 Foam/Rops/RH Lower
36 Foam/Rops/RH Upper
37 Foam/Rops/LH Lower
38 Foam/Rops/LH Upper
39 Foam/Rops/Headliner

Fig. 449 - Interior Trim and Headliner Components

50950457/A0719 272 Printed in U.S.A.

 Cab
Restraint Bar

1 Screw/Shoulder 1/2x1/2 8ZY 7 Bar/Restraint w/Pad 13 Washer, Special

2 Bushing, Oilite, Flanged 8 Switch/Proximity 14 Clip, Christmas Tree
3 LN LG FL SERR 1/4 CZ 9 Magnet/Swich Actuator 15 FW #6 AZY
4 LN CTR 3/8 CBZY 10 Screw Mach Phil 1/4-20-3/4 16 HN MS #540 CZY
5 Stud/Ball 10MM 11 Cover, Restraint Bar Hinge 17 LW ExT T #6 AZY
6 Gas Spring, Seat Bar 12 Stop, Restraint Bar 18 RHMS SLT #540x3/4 CZY

Fig. 450 - Restraint Bar Components

Printed in U.S.A. 273 50950457/A0719

Cab
Control Adjustments
Control Handle Position Adjustment
Control handles are adjusted two ways for proper
operation: a vertically straight appearance and the
handle orientation.
BEFORE beginning this service procedure, per-
form the following SAFETY procedures:
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Remove the floor plate per the “Floor Plate
Removal” on page 290.
2. T-Bar Models; Left control handle: Install
two 3/8” (9.5 mm) alignment rods, one through
the pivot weldment and control weldment, and
the other through the control weldment and the
t-bar pivot (H, Fig. 451). Loosen the jam nuts
on the center control rod and adjust the rod
between the rod ends. Re-tighten the jam nuts.
Next, loosen the jam nuts on the turnbuckles
and adjust the turnbuckles on the hydrostatic
pump arm rods to obtain a 10° forward tilt to the
left handle. Re-tighten the turnbuckle jam nuts.
Remove the temporary alignment rods. MAKE
SURE the adjustment allows for full activation
of the hydrostatic pump arm in both directions
of operation
50950457/A0719
H
Fig. 451 - Left handle alignment rod holes
NOTE: If control handle does not return to
NEUTRAL position after adjustment, refer to the
“Neutral Centering Device” adjustment procedure in
this chapter.
3. T-Bar Models; Right control handle: Remove
the locknut and t-bar stop on the studded rod
end attached to the tilt control rod at the con-
trol handle. Pull the rod end out of the handle.
Remove the locknut on the studded rod end
attached to the lift control rod and the bottom
of the t-bar pivot. Loosen the jam nuts on the
lift and tilt controls rods and adjust rod ends to
obtain a 10° forward tilt (I, Fig. 452) to the con-
trol handle. After adjustment is made, re-tighten
the jam nuts against the rod ends and reconnect
the control rods to the handle and pivot with
their hardware. MAKE SURE the adjustment
allows for full activation of the control valve in
both directions of handle operation.
I
Fig. 452 - Right handle orientation
4. Hand/Foot Models; Left and Right Control
Handles: Loosen the jam nuts and adjust two
turnbuckles (J, Fig. 453) on the hydrostatic
pump arm rods to obtain a 10° forward tilt to the
274 Printed in U.S.A.

control handles. Re-tighten the turnbuckle jam
nuts. MAKE SURE the adjustment allows for
full activation of hydrostatic pump arms in both
directions of handle operation.
Fig. 453 - Location of turnbuckles
Neutral Centering Device Adjustment
These models come equipped with two neutral cen-
tering devices on the hydrostatic pump assembly.
These devices allow the control handles and control
arms to automatically return to NEUTRAL when
the operator releases the control handles.
BEFORE beginning this service procedure, per-
form the following SAFETY procedures:
• Remove attachment from lift arm.
• Raise and block loader so the tires are off
the ground.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Rotate the neutral centering device, checking
the centering torsion spring backlash.
Printed in U.S.A.
Cab
2. Adjust torsion spring backlash by loosening
three lock nuts (K, Fig. 454) on the horizontal
bolts.
Fig. 454 - Torsion springs
3. Rock the upper bracket side-to-side to remove
clearance between the torsion spring “legs” (L,
Fig. 455), neutral adjusting plate, and the pump
arm pin.
Fig. 455 - Torsion spring “legs”.
4. Re-tighten the three lock nuts on the horizontal
bolts.
5. Start the loader. Release the parking brake,
lower the restraint bar down and depress the seat
switch.
6. Run the loader at half throttle and check for
a NEUTRAL setting of the hydrostatic pump
arms. When the pump arms are in NEUTRAL,
the tracks MUST remain stationary.
275 50950457/A0719
Cab
7. To remove any noticeable tire creep, loosen the
lock nuts on bolts at the top of the centering
device (M, Fig. 456), NOT the center bolt. Twist
the upper bracket until any tire creep is elimi-
nated. Re-tighten the lock nuts.
M M
Fig. 456 - Lock nuts on centering device
8. To test the operation of the control handle(s),
move the control handle(s) forward and back-
ward and allow the neutral centering devices
to return the control handles to a NEUTRAL
position.
Lift/Tilt Control Adjustment
BEFORE beginning this service procedure, per-
form the following SAFETY procedures:
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
T-Bar Controls Adjustment
The lift and tilt control rod lengths can be adjusted
to obtain proper position of the T-Bar. Refer to
“Control Handle Position Adjustment” procedure in
this chapter.
50950457/A0719
Hand/Foot Controls Adjustment
1. Remove the floor plate per the “Floor Plate
Removal” on page 290
2. With the lift and tilt spools in NEUTRAL
position, adjust the lift and tilt control cables at
the control valve so that both cables at the foot
pedals are even and parallel to the kickplate.
Tighten the hardware.
3. Reinstall the kickplate.
4. Check for full range of spool travel for both the
lift and tilt cables.
5. Move the lift spool into detent (FLOAT)
position.
6. On the lift pedal: Adjust the length of the lift
control cable. Loosen the jam nut on the cable
until the pedal is level and parallel to the floor
plate.
7. Re-tighten the jam nut.
8. On the tilt pedal: Adjust the length of the tilt
control cable. Loosen the jam nut on the cable
until the tilt pedal matches the position of the
lift pedal.
9. Re-tighten the jam nut.
Hand Throttle Adjustment - Non-DPF
Models
The handle throttle is adjusted at the factory to
provide a full range of engine speed adjustment,
from IDLE to FULL throttle. If the hand throttle is
replaced, it may be necessary to make the following
adjustment.
The hand throttle can be adjusted at four different
locations: (1) at the yoke attached to the throttle
grip, (2) at the yoke on the throttle pivot, (3) at the
ball joint end of the throttle rod, and (4) the clevis
attached to the engine.
276 Printed in U.S.A.
 Cab
Hand Throtttle Tension Adjustment -
Non-DPF Models
Hand throttle tension should be tight enough to
BEFORE beginning this service procedure, per- maintain the desired engine RPM, but loose enough
form the following SAFETY procedures:
to allow easy operation. The hand throttle tension
can be INCREASED or DECREASED.
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
BEFORE beginning this service procedure, per-
(For detailed instructions, refer to the Safety
form the following SAFETY procedures:
chapter of this manual.)
• Shut off the engine.
IMPORTANT: DO NOT attempt to adjust the hand (For detailed instructions, refer to the Safety
throttle lever at the two fuel injection pump adjust- chapter of this manual.)
ment screws.
1. Test the movement of the hand throttle to NOTE: The spring washers and the friction
determine if the cable needs to be shortened washer must be installed properly to provide ten-
or lengthened. When the hand throttle and the sion against the hand throttle.
fuel injection pump are at the low idle position 1. To INCREASE TENSION, tighten the capscrew
simultaneously, proper adjustment is achieved. and locknut that attaches the hand throttle to the
BE SURE that the hand throttle lever does not mainframe.
interfere with the yoke attached to it.
2. To DECREASE TENSION, loosen the cap-
2. If the cable needs adjustment, choose a location screw and locknut that attaches the hand throttle
and: (1) loosen the jam nut on the yoke, clevis to the mainframe.
or ball joint, (2) remove the clevis pin and cotter
pin on the yoke or the ball joint on the ball stud,
(3) twist the yoke or ball joint to shorten or
lengthen the throttle cable as needed, (4) reat-
tach the yoke or ball joint.
3. Push and pull the hand throttle to check for
correct operation. Repeat the adjustment steps
as needed.
4. Tighten the jam nut against the yoke or ball joint
to secure the adjustment.

Printed in U.S.A. 277 50950457/A0719

Cab
Foot Throttle Adjustment - Non-DPF
T-Bar Models
Loaders with T-bar controls include a foot throttle to
control the engine RPM, to match increased power
requirements. The foot throttle is coupled to the
hand throttle through a throttle rod pivot assembly.
The foot throttle is at proper adjustment when push-
ing the hand throttle FULLY FORWARD causes the
foot pedal to be pressed flush against the floor plate.
BEFORE beginning this service procedure, per-
form the following SAFETY procedures:
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
1. Remove the floor plate per the “Floor Plate
Removal” on page 290.
2. With the hand throttle pulled back to the IDLE
position, disconnect the clevis pin attaching the
yoke on the foot pedal assembly.
3. Push down on the foot pedal until it is flush with
the top of the auxiliary control mount weldment.
4. Loosen the jam nut on the yoke of the foot
pedal assembly. Adjust the foot throttle cable
after moving the hand throttle lever to its HIGH
IDLE position. Re-tighten the jam nut on the
yoke.
5. Start the engine and test the foot pedal throttle
for full range of engine speed. Repeat the adjust-
ment steps as needed.
50950457/A0719
Auxiliary Hydraulics Cable Adjustment
The auxiliary hydraulics cable should be adjusted so
that the hydraulic control valve is engaged when the
auxiliary foot pedal is depressed for T-Bar Models,
or, the right control handle cable is locked in ON
position for Hand/Foot models.
BEFORE beginning this service procedure, per-
form the following SAFETY procedures:
• Remove attachment from lift arm.
• Raise lift arm; engage lift arm support
device.
• Shut off the engine.
• Tilt back ROPS/FOPS until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual.)
T-Bar Controls Adjustment
1. Remove the floor plate per the “Floor Plate
Removal” on page 290.
2. With the auxiliary hydraulics spool in
NEUTRAL position, loosen jam nuts on the
auxiliary cable at the pivot foot pedal and adjust
so that the foot pedal is horizontal (level).
3. Disconnect the ball joint on the cable from the
auxiliary pedal assembly by removing the hex
nut.
4. Twist the ball joint in to tighten or out to loosen
the auxiliary hydraulics cable (most adjustments
will require a tightening of the cable).
5. Re-tighten the jam nut snug against the ball joint
to set the adjustment.
6. Reinstall the ball joint and hex nut and secure it
to the auxiliary hydraulics pedal assembly.
7. Check for full range of spool travel. Re-tighten
the jam nuts on the auxiliary cable.
8. Check operation of auxiliary hydraulics cable by
using an appropriate attachment.
278 Printed in U.S.A.

Hand/Foot Controls Adjustment
1. Remove the floor plate per the “Floor Plate
Removal” on page 290.
2. On the control valve, place the auxiliary hydrau-
lics spool in NEUTRAL position.
3. At the right control handle, loosen the jam nut
(N, Fig. 457) securing the auxiliary cable to the
control handle weldment.
Fig. 457 - Jam nut securing auxiliary hydraulics
cable to control handle
4. Right the hand grip of the right control handle
to its most vertical position and check that the
auxiliary spool end at the control valve engages
fully.
5. Check for full-range spool travel in the auxiliary
hydraulics spool on the control valve by using
an appropriate attachment.
Printed in U.S.A.
Cab
ROPS/FOPS Cab
Do not remove or modify the Roll-Over
Protective Structure/Falling Object Protective
Structure (ROPS/FOPS) unless instructed to
do so in Manitou-approved installation instruc-
tions. Modifications, such as welding, drilling
or cutting, can weaken the structure and reduce
the protection it provides. A damaged ROPS/
FOPS cannot be repaired – it must be replaced.
The ROPS/FOPS must be replaced if an rollover
incident occurs. The protection offered by the
ROPS/FOPS will be impaired if it has been dam-
aged in a rollover incident.
Tilt ROPS/FOPS
Tilting up the ROPS/FOPS provides access to
hydraulic, fuel, and electrical components.
Raising ROPS/FOPS
Always secure the ROPS/FOPS to the chassis
with anchor bolts and washers (A, Fig. 458)
before driving or using the machine.
Always close the swing-out cab door (if
equipped) before tilting the ROPS/FOPS.
Stay clear from underneath the ROPS/FOPS as
it is tilted.
Check ROPS/FOPS tilt component condition
at regular intervals. Replace damaged or worn
parts immediately.
1. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
279 50950457/A0719
Cab
2. Remove anchor bolts and washers (A, Fig. 458) Lowering ROPS/FOPS
securing the front of the ROPS/FOPS to the
1. With an assistant’s help, apply upward force on
chassis.
the ROPS/FOOPS while pulling the self-actuat-
ing lock mechanism handle (B, Fig. 459) toward
the front of the loader.
2. Lower the ROPS/FOPS until it contacts the
chassis.
IMPORTANT: Avoid damaging control handles by
slowly lowering the ROPS/FOPS. MAKE SURE the
A
control handles clear the ROPS/FOPS.

Stay clear from underneath the ROPS/FOPS as

it is tilted down. Injury to limbs can result.

Fig. 458 - ROPS/FOPS Anchor Fastener

3. Secure the ROPS/FOPS to the chassis with
IMPORTANT: BEFORE raising the ROPS/FOPS,
position the seat as far back as it will go. Avoid
anchor bolts, and washers. Torque anchor bolts
damaging control handles by slowly raising the to 102 Nm (75 lb.-ft.).
ROPS/FOPS. BE SURE the control handles clear
the ROPS/FOPS.
3. On machines equipped with a swing-out cab
Always secure the ROPS/FOPS to the chassis
door, securely close and latch the door. with anchor bolts and washers (A, Fig. 458)
4. Close the engine cover. before driving or using the machine.

5. Lift ROPS/FOPS up and tilt it back until the

self-actuating lock mechanism engages. The
lock mechanism locks the ROPS/FOPS in a
rolled-back position (B, Fig. 459).

Fig. 459 - ROPS/FOPS lock shown engaged

NOTE: Gas springs balance the ROPS/FOPS to

aid raising and lowering.

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 Cab

ROPS/FOPS/Cab Removal 2. Raise and support the lift arm (A, Fig. 460)
using the lift arm support device (B, Fig. 460).
NOTE: Some machines may vary slightly from
what is shown in the photographs in this procedure.
NOTE: Label all hoses and note their locations
B
before disconnecting to ensure correct installation.
IMPORTANT: Park the machine where the
ROPS/FOPS can be supported with an overhead A
hoist or similar device.

The ROPS/FOPS weighs approximately 250 kg

(550 lbs). Use proper lifting equipment of suffi-
cient capacity. Lifting the ROPS/FOPS without
proper equipment could result in serious per-
sonal injury or equipment damage. Keep clear
of suspended loads.
NOTE: Some loss of hydraulic oil will occur when
disconnecting hydraulic hoses. Use absorbent mats
to catch any dripping oil when disconnecting hoses.
Cap and plug hydraulic lines after disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws or take to a recy-
cling center for proper disposal. DO NOT pour onto
the ground or down a drain.
1. Remove the attachment.
Fig. 460 - Lift Arm Support Device
3. Perform the “Mandatory Safety Shutdown
Procedure” on page 16.
4. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
5. Remove the engine access cover. See “Engine
Access Cover” in this section for more
information.
6. Remove the two capscrews, washers, and nuts
(C, Fig. 461) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (D, Fig. 461) to the machine.

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.

D C

Fig. 461 - ROPS/FOPS Mounting Hardware

Printed in U.S.A. 281 50950457/A0719

Cab

9. Disconnect the two ROPS/FOPS electrical con-

nectors (H, Fig. 464).
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

7. Raise the ROPS/FOPS until the safety latch (E,

Fig. 462) is engaged.
H

E Fig. 464 - ROPS/FOPS Electrical Connector

10. Remove the capscrew and P-clip (I, Fig. 465)

that secure the ROPS/FOPS wiring harness to
the machine
11. Loosen the two hose clamps (J, Fig. 465). Tag
and disconnect the two heater coolant hoses (K,
Fig. 465). Close all openings using caps and
Fig. 462 - ROPS/FOPS Safety Latch plugs.
8. Remove the two capscrews (F, Fig. 463) that
secure the ROPS/FOPS electrical connector
cover (G, Fig. 463) to the machine.

F G

J K

Fig. 465 - ROPS/FOPS Heater Hoses

Fig. 463 - ROPS/FOPS Electrical Connector Cover

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 Cab

13. Remove the capscrew and nut (M, Fig. 467)

securing the ROPS/FOPS safety latch (N, Fig.
467) to the ROPS/FOPS.
Removal of the ROPS/FOPS safety latch will
place all of the weight of the ROPS/FOPS on the
gas struts. During the following steps, DO NOT
allow anyone under the ROPS/FOPS if there is
not an appropriate supporting device in place.

NOTE: The ROPS/FOPS weight is approximately M

550 lbs. (250 kg).
12. Attach an appropriate lifting device (L, Fig.
466) to the front of the ROPS/FOPS.
N

Fig. 467 - ROPS/FOPS Safety Latch Mounting

L Hardware

14. Raise the ROPS/FOPS until the gas struts are

fully extended.
15. Remove the upper mounting capscrew (O, Fig.
468) on the gas strut (P, Fig. 468). Repeat for
the opposite side.

Fig. 466 - ROPS/FOPS Front Lifting Device

NOTE: After removing the ROPS/FOPS safety

latch, the ROPS/FOPS will want to raise. Use the
aid of an assistant to control the movement of the
ROPS/FOPS. O

Fig. 468 - ROPS/FOPS Gas Strut Upper Mounting

Hardware

16. Lower the ROPS/FOPS.

Printed in U.S.A. 283 50950457/A0719

Cab
18. With the aid of an assistant, remove the ROPS/
17. Reset the lifting device (Q, Fig. 469) to support FOPS rear mounting capscrews (R, Fig. 470)
the entire ROPS/FOPS. and remove the ROPS/FOPS from the machine.

R
Q

Fig. 470 - ROPS/FOPS Rear Mounting Hardware

Fig. 469 - ROPS/FOPS Lifting Device

ROPS/FOPS Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this procedure.
IMPORTANT: Always verify electrical connections
are sound and strain relieved when static and to
accommodate moving components and machine
operation. Route, tie, and clamp all wires and con-
nections to avoid pinching, chaffing, and damage
consistent with factory design and practice.
IMPORTANT: The ROPS/FOPS must be lifted/
supported with an overhead hoist or similar device
of sufficient capacity

The ROPS/FOPS weighs approximately 250 kg

(550 lb.). Use proper lifting equipment of suffi-
cient capacity. Lifting the ROPS/FOPS without
proper equipment could result in serious per-
sonal injury or equipment damage.

NOTE: An assistant is required for steps 1–4.

NOTE: Keep clear of suspended loads..

1. Using an overhead hoist or other appropriate
lifting device (A, Fig. Fig. 471), lift ROPS/
FOPS into position on the machine.

50950457/A0719 284 Printed in U.S.A.


Keep hands and feet clear when positioning the
ROPS/FOPS on the machine. Severe pinching/
crushing injury can occur.
Fig. 471 - ROPS/FOPS Lifting Device
NOTE: To aid in the installation of the engine
access cover, when installing the ROPS/FOPS left
mounting capscrew, only install the capscrew as far
as the ROPS/FOPS mounting bracket.
NOTE: While lowering the ROPS/FOPS, make
sure no wires or hoses are being pinched or cut.
2. Install the ROPS/FOPS rear mounting cap-
screws (B, Fig. 472). Do not install the washers
and nuts at this time.
B D
Fig. 472 - ROPS/FOPS Rear Mounting Hardware
Printed in U.S.A.
Cab
3. Reset the lifting device (C, Fig. 473) to sup-
port the front of the ROPS/FOPS and raise the
ROPS/FOPS.
C
Fig. 473 - ROPS/FOPS Front Lifting Device
Always secure the ROPS/FOPS in the tilted
position with a suitable supporting device.
Never allow anyone under the ROPS/FOPS if it
is not securely supported.
4. Install the gas strut (D, Fig. 474), securing it
to the ROPS/FOPS with the capscrew (E, Fig.
474). Tighten the capscrew securely. Repeat for
the opposite side.
E
Fig. 474 - ROPS/FOPS Gas Strut Upper Mounting
Hardware
NOTE: With the gas struts attached, the ROPS/
FOPS will want to raise. Use the aid of an assistant
to control the movement of the ROPS/FOPS.
285 50950457/A0719
Cab
5. With the aid of an assistant, lower the cab and
install the ROPS/FOPS safety latch (F, Fig. 9. Connect the ROPS/FOPS electrical connectors
475), securing it with the capscrew and nut (G, (K, Fig. 477).
Fig. 475). Tighten the nut securely.

K
G

F
Fig. 477 - ROPS/FOPS Electrical Connector
Fig. 475 - ROPS/FOPS Safety Latch Mounting
Hardware 10. Install the ROPS/FOPS electrical connector
cover (L, Fig. 478), securing it with the two
6. Make sure the ROPS/FOPS safety latch is capscrews (M, Fig. 478).
engaged and remove the lifting device from the
ROPS/FOPS.
7. Install the two heater coolant hoses (H, Fig.
476), securing them with the two hose clamps
(I, Fig. 476). Tighten the hose clamps securely.
L
8. Install the ROPS/FOPS wiring harness P-clip (J, M
Fig. 476), securing it with the capscrew. Tighten
the capscrew securely.

Fig. 478 - ROPS/FOPS Electrical Connector Cover

I H

Fig. 476 - ROPS/FOPS heater hoses

50950457/A0719 286 Printed in U.S.A.

 Cab

11. Disengage the ROPS/FOPS safety latch (N, Fig. 16. Disengage the lift arm support device (P, Fig.
479) and lower the ROPS/FOPS. 481) and lower the lift arm (Q, Fig. 481).

N Q

Fig. 479 - ROPS/FOPS Safety Latch Fig. 481 - Lift Arm Support Device

12. Install the two capscrews, washers, and nuts 17. Install the attachment.
(O, Fig. 480) that secure the ROPS/FOPS to
18. Stop engine.
the machine. Tighten the capscrews and nuts
securely.

Fig. 480 - ROPS/FOPS Mounting Hardware

13. Install the engine access cover. See “Engine

Access Cover” in this section for more
information.
14. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
15. Start the engine and check for proper machine
operation.

Printed in U.S.A. 287 50950457/A0719

Cab

Restraint Bar Removal/

5. Remove the restraint bar right side mounting
Installation capscrew washer, and nut (D, Fig. 484).
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Restraint Bar Removal

1. Perform the “Mandatory Safety Shutdown
Procedure” on page 16. D
2. Disconnect the gas strut (A, Fig. 482) from the
left side of the restraint bar (B, Fig. 482).

Fig. 484 - Restraint Bar Right Mounting Hardware

A 6. Remove the restraint bar from the machine.

Restraint Bar Installation

1. Place the restraint bar in position.
2. Install the restraint bar right side mounting
capscrew, washer, and nut (A, Fig. 485). Tighten
the nut securely.
Fig. 482 - Restraint Bar Gas Strut

3. Lower the restraint bar.

4. Remove the restraint bar left side mounting cap-
screw, washer, and nut (C, Fig. 483).

C
Fig. 485 - Restraint Bar Right Mounting Hardware

Fig. 483 - Restraint Bar Left Mounting Hardware

50950457/A0719 288 Printed in U.S.A.

 Cab
2. Open the engine access door.
3. Install the restraint bar left side mounting cap-
NOTE: The hitch weighs approximately 250 lb.
screw, washer, and nut (B, Fig. 486). Tighten the
(113 kg).
nut securely.
3. Support the hitch (A, Fig. 488) with an appro-
priate lifting device (B, Fig. 488).

B
Fig. 486 - Restraint Bar Left Mounting Hardware
Fig. 488 - Hitch Supporting Device
4. Raise the arm and connect the gas strut (C, Fig.
4. Remove the two mounting capscrews, washers,
487) to the right side of the restraint bar.
and nuts (C, Fig. 489).

C C

Fig. 487 - Restraint Bar Gas Strut

5. Start the engine and check for proper machine Fig. 489 - Hitch Mounting Hardware
operation.
5. Lower the hitch to remove it from the machine.
6. Stop the engine.
Hitch Installation
NOTE: The hitch weighs approximately 250 lb.
Hitch Removal/Installation (113 kg).
NOTE: Some machines may vary slightly from 1. Raise the hitch (A, Fig. 490) into position on the
what is shown in the photographs in this manual.
machine using an appropriate lifting device (B,
Procedures are similar, however, in all cases.
Fig. 490).
2. Install the two mounting capscrews, washers
Hitch Removal
and nuts (C, Fig. 490). Tighten the nuts securely.
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.

Printed in U.S.A. 289 50950457/A0719

Cab

Floor Plate Removal/Installation

NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
C

Floor Plate Removal

1. Remove the attachment.
A

B
Fig. 490 - Hitch Installation
3. Close the engine access door.
Hose removal or component failure can cause
the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.

2. Raise and support the lift arm (A, Fig. 491)

using the lift arm support device (B, Fig. 491).

Fig. 491 - Lift Arm Support Device

3. Complete the “Mandatory Safety Shutdown

Procedure” on page 16.

50950457/A0719 290 Printed in U.S.A.

 Cab

4. Loosen the four capscrews (C, Fig. 492) that
secure the front access plate (D, Fig. 492) to the
machine, and remove the front access plate from
the machine.
6. Loosen the three capscrews and nuts (G, Fig.
494) that secure the electronic foot throttle (H,
Fig. 494) to the machine.
H

D
C G

Fig. 494 - Electronic Foot Throttle Hardware

Fig. 492 - Front Access Cover
7. Open the rollover protection structure (ROPS)/
5. Remove the four capscrews (E, Fig. 493) that falling object protective structure (FOPS) door.
secure the floor pan (F, Fig. 493) to the machine. (I, Fig. 495)
Remove the floor pan from the machine.

Fig. 493 - Floor Pan

Fig. 495 - ROPS/FOPS Door

Printed in U.S.A. 291 50950457/A0719

Cab

8. Remove the four capscrews (J, Fig. 496) that 2. Secure the front of the floor plate to the machine
secure the rear of the floor plate (K, Fig. 496) to using the two capscrews (A, Fig. 498). Tighten
the kick plate (L, Fig. 496). the capscrews securely.

J J

K A
L

Fig. 496 - Kick Plate Mounting Hardware

9. Remove the two capscrews (M, Fig. 497) that

secure the front of the floor plate (N, Fig. 497)
Fig. 498 - Floor Plate Mounting Hardware
to the machine.
3. Secure the rear of the floor plate to the machine
using four capscrews (B, Fig. 499). Tighten the
N capscrews securely.

M B B

Fig. 497 - Floor Plate Mounting Hardware

10. Remove the floor plate from the machine. Fig. 499 - Kick Plate Mounting Hardware

4. Close the rollover protection structure (ROPS)/

Floor Plate Installation falling object protective structure (FOPS) door.
1. Place the floor plate in position in the machine.

50950457/A0719 292 Printed in U.S.A.


5. Install the electronic foot throttle, securing it to
the machine with the three capscrews and nuts
(C, Fig. 500). Tighten the nuts securely.
Fig. 500 - Electronic Foot Throttle Hardware
6. Install the floor pan (D, Fig. 501), securing it
to the machine with the four capscrews (E, Fig.
501). Tighten the capscrews securely.
E
D H
Fig. 501 - Floor Pan
Printed in U.S.A.
Cab
7. Install the front access cover, securing it to the
machine using the four capscrews (F, Fig. 502).
Tighten the capscrews securely.
Fig. 502 - Front Access Cover
8. Start the engine and check for proper machine
operation.
9. Disengage the lift arm support device (G, Fig.
503) and lower the lift arm (H, Fig. 503).
G
Fig. 503 - Lift Arm Support Device
10. Install the attachment.
11. Stop the engine.
293 50950457/A0719
Cab

Crossmember Removal/
5. Remove the left side crossmember mounting
Installation capscrew (D, Fig. 505).
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Crossmember Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16. D

2. Remove the pivot tube assembly. See “Pivot

Tube Assembly” in the Controls section for
more information.
3. Remove the control handle. See “Control Fig. 505 - Crossmember Left Side Mounting
Handle” in the Controls section for more Hardware
information. 6. Remove the right side crossmember mounting
4. Remove the nut (A, Fig. 504) connecting the capscrew, washer, and nut (E, Fig. 506).
centering rod (B, Fig. 504) to the crossmember
(C, Fig. 504).

C
A

B E

Fig. 506 - Crossmember Right Side Mounting

Hardware
Fig. 504 - Centering Rod
7. Remove the crossmember from the machine.

Crossmember Installation
1. Place the crossmember in position on the
machine.

50950457/A0719 294 Printed in U.S.A.


2. Install the left side mounting capscrew (A, Fig.
507). Tighten the capscrew securely.
A D
Fig. 507 - Crossmember Left Side Mounting
Hardware
3. Install the right side mounting capscrew, washer,
and nut (B, Fig. 508). Tighten the nut securely
Fig. 508 - Crossmember Right Side Mounting
Hardware.
Printed in U.S.A.
Cab
4. Install the nut (C, Fig. 509) connecting the
centering rod (D, Fig. 509) to the crossmember.
Tighten the nut securely.
Fig. 509 - Centering Rod
5. Install the control handle. See “Control Handle”
in the Controls section for more information.
6. Install the pivot tube assembly. See “Pivot Tube
Assembly” in the Controls section for more
information.
295 50950457/A0719
Cab

Pivot Tube Assembly Removal/

3. Raise the ROPS/FOPS until the safety latch (C,
Installation Fig. 511) is engaged.
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Pivot Tube Assembly Removal

1. Complete the “Mandatory Safety Shutdown C
Procedure” on page 16.
2. Remove the two capscrews, washers, and nuts
(A, Fig. 510) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 510) to the machine.

Fig. 511 - ROPS/FOPS Safety Latch

B
4. Remove the six capscrews (D, Fig. 512) that
secure the travel control handle boot cover to
the kick plate.
5. Remove the six capscrews (E, Fig. 512) that
secure the tilt control handle boot cover to the
A
kick plate.
6. Remove the eight capscrews (F, Fig. 512) that
secure the kick plate to the machine.

F F
Fig. 510 - ROPS/FOPS Mounting Hardware

Always raise the ROPS/FOPS completely, allow-

ing the safety latch to engage. Never allow any- E D
one to be under the ROPS/FOPS if the safety
latch is not engaged.

F F

Fig. 512 - Kick Plate Mounting Hardware

50950457/A0719 296 Printed in U.S.A.


7. Remove the two capscrews (G, Fig. 513) that
secure the front of the floor plate (H, Fig. 513)
to the machine.
Cab
10. Remove the two capscrews and nuts (K, Fig.
515) connecting the travel control rods (L, Fig.
515) to the hydrostatic pump (M, Fig. 515).

H K

M
L

G
K

Fig. 513 - Floor Plate Mounting Hardware

8. Lift the floor plate (I, Fig. 514), and loosen
the two capscrews (J, Fig. 514) that secure the
lower part of the kick plate to the machine.
Fig. 515 - Travel Control Rods
11. Remove the nut (N, Fig. 516) connecting the
travel control rod (O, Fig. 516) to the drive con-
trol weldment (P, Fig. 516).

J
I

P
N

Fig. 514 - Kick Plate Lower Mounting Hardware

Fig. 516 - Drive Control Weldment
9. Remove the kick plate from the machine.

Printed in U.S.A. 297 50950457/A0719

Cab
12. Remove the two capscrews and nuts (Q, Fig.
517) that secure the drive control pivot flange
(R, Fig. 517) to the crossmember.
Q
R
Fig. 517 - Drive Control Pivot Flange Hardware
13. Remove the flange from the crossmember.
14. Lift the drive control pivot weldment (S,
Fig. 518) to remove it from the lower flange.
Remove the pivot tube assembly from the
machine.
15. Once out of the machine, remove the nuts (T,
Fig. 518) that secure the control rods (U, Fig.
518) to the drive control pivot weldment.
U (E, Fig. 520). Tighten the nuts securely.
S
T D
Fig. 518 - Pivot Tube Assembly and Hardware
50950457/A0719
Pivot Tube Assembly Installation
1. Install the control rods (A, Fig. 519) on the drive
control pivot weldment (B, Fig. 519), securing
them with the nuts (C, Fig. 519). Tighten the
nuts securely.
B
C
Fig. 519 - Pivot Tube Assembly and Hardware
2. Install the pivot tube assembly on the machine
by inserting the assembly into the crossmember.
Once the assembly is in the crossmember, insert
the drive control pivot weldment into the lower
flange.
3. Install the upper flange (D, Fig. 520) over the
drive control pivot weldment, securing it to the
crossmember with the two capscrews and nuts
E
Fig. 520 - Drive Control Pivot Flange Hardware
298 Printed in U.S.A.

4. Connect the travel control rod to the drive con-
trol weldment (F, Fig. 521), securing it with the
nut (G, Fig. 521). Tighten the nut securely.
F
G
Fig. 521 - Drive Control Weldment
5. Connect the two travel control rods to the
hydrostatic pump, securing it with the two cap-
screws and nuts (H, Fig. 522). Tighten the nuts
securely.
Fig. 522 - Travel Control Rods
Printed in U.S.A.
Cab
6. Install the kick plate, making sure to align the
kick plate with the two bottom capscrews (I,
Fig. 523). Tighten the capscrews securely.
Fig. 523 - Kick Plate Lower Mounting Hardware
7. Install the two capscrews (J, Fig. 524) securing
the front of the floor plate to machine. Tighten
the capscrews securely.
Fig. 524 - Floor Plate Mounting Hardware
8. Install the remaining eight capscrews (K, Fig.
525) securing the kick plate to the machine.
Tighten the capscrews securely.
9. Install the tilt control boot cover, securing it to
the machine using the six capscrews (L, Fig.
525). Tighten the capscrews securely.
299 50950457/A0719
Cab

10. Install the travel control boot cover, securing it
to the machine using the six capscrews (M, Fig.
525). Tighten the capscrews securely.
K K
12. Install the two capscrews, washers, and nuts
(O, Fig. 527) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.

L M

K K

Fig. 525 - Kick Plate Mounting Hardware

11. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (N, Fig. 526) and lower the
ROPS/FOPS.
Fig. 527 - ROPS/FOPS Mounting Hardware
13. Start the engine and check for proper machine
operation.

Fig. 526 - ROPS/FOPS Safety Latch

50950457/A0719 300 Printed in U.S.A.

 Cab

Lift/Tilt Control Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
4. Remove the two capscrews, washers, and nuts
(C, Fig. 529) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (D, Fig. 529) to the machine.

Lift/Tilt Control Removal

1. Remove the attachment.

D C

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for
service.
Fig. 529 - ROPS/FOPS Mounting Hardware

2. Raise and support the lift arm (A, Fig. 528)

using the lift arm support device (B, Fig. 528).
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
B latch is not engaged.

A 5. Raise the ROPS/FOPS until the safety latch (E,

Fig. 530) is engaged.

E
Fig. 528 - Lift Arm Support Device

3. Complete the mandatory safety shutdown

procedure

Fig. 530 - ROPS/FOPS Safety Latch

Printed in U.S.A. 301 50950457/A0719

Cab
6. Remove the nut (H, Fig. 531) securing the tilt
control rod (I, Fig. 531) to the lift/tilt control
handle (J, Fig. 531). Remove the tilt control rod
and set it aside.
I
Fig. 531 - Tilt Control Rod
7. Remove the lift/tilt control handle from machine
by firmly pulling the handle upward.
8. Remove the nut (K, Fig. 532) securing the lift
control rod (L, Fig. 532) to the lift/tilt control
lever bracket (M, Fig. 532). Remove the lift
control rod and set it aside.
M
K
Fig. 532 - Lift Control Rod
50950457/A0719
9. Remove the two capscrews and nuts (N, Fig.
533) securing the lift/tilt control lever bracket to
the machine.
Fig. 533 - Lift/Tilt Control Lever Bracket
10. Remove the lift/tilt control lever bracket from
the machine.
Lift/Tilt Control Installation
1. Install the lift/tilt control lever bracket (A, Fig.
534), securing it to the machine with the two
capscrews and nuts (B, Fig. 534). Tighten the
nuts securely.
A
Fig. 534 - Lift/Tilt Control Lever Bracket
302 Printed in U.S.A.

2. Connect the lift control rod (C, Fig. 535), secur-
ing it to the lift/tilt control lever bracket with the
nut (D, Fig. 535). Tighten the nut securely.
D
Fig. 535 - Lift Control Rod
3. Install the lift/tilt control handle by inserting
the control handle through the top and bottom
flanges.
4. Connect the tilt control rod (E, Fig. 536), secur-
ing it to the lift/tilt control handle with the nut
(F, Fig. 536). Tighten the nut securely.
E
Fig. 536 - Tilt Control Rod
Printed in U.S.A.
Cab
5. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (G, Fig. 537) and lower the
ROPS/FOPS.
G
Fig. 537 - ROPS/FOPS Safety Latch
6. Install the two capscrews, washers, and nuts
(H, Fig. 538) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.
Fig. 538 - ROPS/FOPS Mounting Hardware
303 50950457/A0719
Cab
7. Start the engine and check for proper machine
operation. 2. Raise and support the lift arm (A, Fig. 540)
using the lift arm support device (B, Fig. 540).
8. Disengage the lift arm support device (I, Fig.
539) and lower the lift arm (J, Fig. 539).

I
A

Fig. 540 - Lift Arm Support Device

Fig. 539 - Lift Arm Support Device
9. Install the attachment.
10. Stop the engine.
Electronic Foot Throttle
Removal/Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
Electronic Foot Throttle Removal
3. Complete the mandatory safety shutdown
procedure.
4. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
5. Loosen the four capscrews (C, Fig. 541) secur-
ing the front access plate (D, Fig. 541) to the
machine, and remove the front access plate from
the machine.
D
C

1. Remove the attachment.

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
Fig. 541 - Front Access Cover
port device when leaving the lift arm raised for
service.

50950457/A0719 304 Printed in U.S.A.

 Cab
8. Remove the four capscrews (I, Fig. 544) that
6. Remove the four capscrews (E, Fig. 542) that secure the rear of the floor plate (J, Fig. 544) to
secure the floor pan (F, Fig. 542) to the machine. the kick plate (K, Fig. 544).
Remove the floor pan from the machine.

I I

E
J
F K

Fig. 544 - Kick Plate Mounting Hardware

Fig. 542 - Floor Pan 9. Remove the two capscrews (L, Fig. 545) that
secure the front of the floor plate (M, Fig. 545)
7. Remove the three capscrews and nuts (G, Fig.
to the machine.
543) that secure the electronic foot throttle (H,
Fig. 543) to the machine.
M

G
L

V
Fig. 545 - Floor Plate Mounting Hardware

Fig. 543 - Electronic Foot Throttle Hardware 10. Remove the floor plate from the machine.

Printed in U.S.A. 305 50950457/A0719

Cab
11. Disconnect the electronic foot throttle electrical 3. Place the floor plate in the machine. Do not
connector (N, Fig. 546). install the capscrews at this time.
4. Install the electronic foot throttle, securing it to
the machine with the three capscrews and nuts
(B, Fig. 548). Tighten the nuts securely.

N B

Fig. 546 - Electronic Foot Throttle Electrical

Connector.

12. Remove the electronic foot throttle from the

machine.
Fig. 548 - Electronic Foot Throttle Hardware

Electronic Foot Throttle Installation
1. Place the electronic foot throttle in the machine.
2. Connect the electronic foot throttle electrical
connector (A, Fig. 547).
5. Install the floor pan (C, Fig. 549), securing it to
the machine with the four capscrews (D, Fig.
549). Tighten the capscrews securely.

A
Fig. 549 - Floor Pan

Fig. 547 - Electronic Foot Throttle Electrical

Connector

50950457/A0719 306 Printed in U.S.A.


6. Install the front access cover, securing it to the
machine using the four capscrews (E, Fig. 550).
Tighten the capscrews securely.
Fig. 550 - Front Access Cover
7. Secure the front of the floor plate to the machine
using the two capscrews (F, Fig. 551). Tighten
the capscrews securely.
F I
Fig. 551 - Floor Plate Mounting Hardware
Printed in U.S.A.
Cab
8. Secure the rear of the floor plate to the machine
using four capscrews (G, Fig. 552). Tighten the
capscrews securely.
G G
Fig. 552 - Kick Plate Mounting Hardware
9. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
10. Start the engine and check for proper machine
operation.
11. Disengage the lift arm support device (H, Fig.
553) and lower the lift arm (I, Fig. 553).
Fig. 553 - Lift Arm Support Device
12. Install the attachment.
13. Stop the engine.
307 50950457/A0719
Cab

Seat Removal/Installation
NOTE: Some machines may vary slightly from C
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Seat Removal
1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16. B

2. Disconnect the negative (-) battery cable at the

battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
Fig. 555 - ROPS/FOPS Mounting Hardware
3. Disconnect the operator presence switch electri-
cal connector (A, Fig. 554) located behind the
operator’s seat.

Always raise the ROPS/FOPS completely, allow-

ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

5. Raise the ROPS/FOPS until the safety latch (D,

Fig. 556) is engaged.
A

Fig. 554 - Presence Switch Electrical Connector

4. Remove the two capscrews, washers, and nuts

(B, Fig. 555) securing the rollover protection D
structure (ROPS)/falling object protective struc-
ture (FOPS) (C, Fig. 555) to the machine.

Fig. 556 - ROPS/FOPS Safety Latch

50950457/A0719 308 Printed in U.S.A.

 Cab
6. Remove four capscrews (E, Fig. 557) from the 2. Disengage the ROPS/FOPS safety latch (C, Fig.
bottom of the ROPS/FOPS and remove the 559) and lower the ROPS/FOPS.
operator’s seat (F, Fig. 557) from the machine.

E C

Fig. 559 - ROPS/FOPS Safety Latch

Fig. 557 - Operator Seat Removal
3. Install the two capscrews, washers, and nuts
(D, Fig. 560) securing the ROPS/FOPS (E, Fig.
Installation 560) to the machine. Tighten the nuts securely.
1. Place the operator’s seat (A, Fig. 558) inside the
machine, securing it with the four capscrews (B,
Fig. 558) at the bottom of the rollover protection E
structure (ROPS)/falling object protective struc-
ture (FOPS) Tighten the capscrews securely.

B
Fig. 560 - ROPS/FOPS Mounting Hardware

Fig. 558 - Operator Seat Removal

Printed in U.S.A. 309 50950457/A0719

Cab
4. Connect the operator presence switch electrical
connector (F, Fig. 561) located behind the oper-
ator’s seat.
F 1. Complete the “Mandatory Safety Shutdown
Fig. 561 - Operator Presence Switch electrical
Connector
5. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
6. Turn on the machine to check for proper func-
tion of operator presence switch.
7. Turn off the machine.
50950457/A0719
Control Handle Removal/
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: The travel control handle is shown for the
removal and installation procedures. The removal
and installation of the lift/tilt control lever is similar.
Control Handle Removal
Procedure” on page 16.
2. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
3. Remove the two capscrews, washers, and nuts
(A, Fig. 562) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 562) to the machine.
B
Fig. 562 - ROPS/FOPS Mounting Hardware
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.
310 Printed in U.S.A.

4. Raise the ROPS/FOPS until the safety latch (C,
Fig. 563) is engaged.
Fig. 563 - ROPS/FOPS Safety Latch
5. Remove the six capscrews (D, Fig. 564) that
secure the travel control handle boot cover to
the kick plate.
6. Remove the six capscrews (E, Fig. 564) that
secure the tilt control handle boot cover to the
kick plate.
7. Remove the eight capscrews (F, Fig. 564) that
secure the kick plate to the machine.
F F
E D
F F
Fig. 564 - Kick Plate Mounting Hardware
Printed in U.S.A.
Cab
8. Remove the two capscrews (G, Fig. 565) that
secure the front of the floor plate (H, Fig. 565)
to the machine.
Fig. 565 - Floor Plate Mounting Hardware
9. Lift up on the floor plate (I, Fig. 566), and
loosen the two capscrews (J, Fig. 566) that
secure the lower part of the kick plate to the
machine.
J
I
Fig. 566 - Kick Plate Lower Mounting Hardware
10. Remove the kick plate from the machine.
311 50950457/A0719
Cab
11. Cut the wire ties (K, Fig. 567) that secure the
horn wiring harness to the machine. Tag and
disconnect the horn electrical connectors (L,
Fig. 567).
Fig. 567 - Horn Wiring Harness
12. Remove the two capscrews and nuts (M, Fig.
568) that secure the control handle flange (N,
Fig. 568) to the crossmember (O, Fig. 568).
M
N
O
Fig. 568 - Control Handle Flange Hardware
50950457/A0719
13. Remove the capscrew and nut (P, Fig. 569) that
secure the control handle to the drive control
weldment (Q, Fig. 569).
Fig. 569 - Control Handle Mounting Hardware
14. Remove the control handle from the machine by
firmly pulling the handle up.
Control Handle Installation
1. Install the control handle by inserting the handle
through the drive control weldment and into the
bottom flange.
2. Secure the control handle to the drive control
weldment with the capscrew and nut (A, Fig.
570). Tighten the capscrew and nut securely.
A
Fig. 570 - Control Handle Mounting Hardware
312 Printed in U.S.A.

3. Install the upper flange (B, Fig. 571), securing it
to the crossmember with the two capscrews and
nuts (C, Fig. 571). Tighten the capscrews and
nuts securely.
C
B
Fig. 571 - Control Handle Flange Hardware
4. Connect the horn electrical connectors (D,
Fig. 572), and secure the wiring harness to the
machine using wire ties (E, Fig. 572).
Fig. 572 - Horn Wiring Harness
Printed in U.S.A.
Cab
5. Install the kick plate, making sure to align the
kick plate with the two bottom capscrews (F,
Fig. 573). Tighten the capscrews securely.
Fig. 573 - Kick Plate Lower Mounting Hardware
6. Install the two capscrews (G, Fig. 574) securing
the front of the floor plate to machine. Tighten
the capscrews securely.
Fig. 574 - Floor Plate Mounting Hardware
7. Install the remaining eight capscrews (H, Fig.
575) securing the kick plate to the machine.
Tighten the capscrews securely.
8. Install the tilt control boot cover, securing it
to the machine using the six capscrews (I, Fig.
575). Tighten the capscrews securely.
313 50950457/A0719
Cab
9. Install the travel control boot cover, securing it
to the machine using the six capscrews (J, Fig.
575). Tighten the capscrews securely.
H H
I J
H H
Fig. 575 - Kick plate Mounting Hardware
10. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (K, Fig. 576) and lower the
ROPS/FOPS.
Fig. 576 - ROPS/FOPS Safety Latch
50950457/A0719
11. Install the two capscrews, washers, and nuts
(L, Fig. 577) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.
Fig. 577 - ROPS/FOPS Mounting Hardware
12. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
13. Start the engine and check for proper machine
operation.
314 Printed in U.S.A.
 Cab

Heater Removal/Installation 3. Complete the “Mandatory Safety Shutdown

Procedure” on page 16.
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual. 4. Disconnect the negative (-) battery cable at the
Procedures are similar, however, in all cases. battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
NOTE: Label all hoses and note their locations
from the battery terminals.
before disconnecting them to ensure correct
installation. 5. Remove the 10 capscrews (C, Fig. 579) that
secure the heater filter and blower access cover
NOTE: Some loss of coolant will occur when dis-
connecting coolant hoses. Use absorbent mats to to the rollover protection structure (ROPS)/fall-
catch any dripping fluid when disconnecting hoses. ing object protective structure (FOPS).
Cap and plug coolant hoses after disconnecting.
IMPORTANT: Always dispose of coolant fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
C
fluids onto the ground or down a drain.

Heater Removal
1. Remove the attachment.

Hose removal or component failure can cause

the lift arm to drop. Always use the lift arm sup-
port device when leaving the lift arm raised for Fig. 579 - Heater Filter Access Cover
service.
6. Remove the two capscrews, washers, and nuts
(D, Fig. 580) securing the ROPS/FOPS (E, Fig.
2. Raise and support the lift arm (A, Fig. 578) 580) to the machine.
using the lift arm support device (B, Fig. 578).

A E
D

Fig. 580 - ROPS/FOPS Mounting Hardware

Fig. 578 - Lift Arm Support Device

Printed in U.S.A. 315 50950457/A0719

Cab
10. Loosen the temperature control cable clamp
(I, Fig. 583) and disconnect cable (J, Fig. 583)
from heater unit.
Always raise the ROPS/FOPS completely, allow-
ing the safety latch to engage. Never allow any-
one to be under the ROPS/FOPS if the safety
latch is not engaged.

7. Raise the ROPS/FOPS until the safety latch (F, I

Fig. 581) is engaged.

Fig. 583 - Heater Temperature Control Cable

F
11. Disengage the ROPS/FOPS safety latch (K, Fig.
584) and lower the ROPS/FOPS.

Fig. 581 - ROPS/FOPS Safety Latch

8. Loosen the two hose clamps (G, Fig. 582).

9. Tag and disconnect the two coolant hoses (H,
Fig. 582) from the heater assembly. Close all
openings using caps and plugs. K

H
G Fig. 584 - ROPS/FOPS Safety Latch

Fig. 582 - Heater Hoses

50950457/A0719 316 Printed in U.S.A.
 Cab
12. Disconnect the heater ground electrical connec- Heater Installation
tor (L, Fig. 585) from the heater assembly.
1. Connect the heater positive connector cable (A,
Fig. 587) to the heater assembly.

Fig. 585 - Heater Ground Connector

13. Disconnect the positive connector (M, Fig. 586) Fig. 587 - Heater Positive Connector
from the heater assembly.
2. Connect the heater ground connector cable (B,
Fig. 588) to the heater assembly.

M B

Fig. 586 - Heater Positive Connector

Fig. 588 - Heater Ground Connector

14. Remove the heater assembly from the machine.

Printed in U.S.A. 317 50950457/A0719

Cab

Always raise the rollover protection struc-

ture (ROPS)/falling object protective structure
(FOPS) completely, allowing the safety latch D
to engage. Never allow anyone to be under the E
ROPS/FOPS if the safety latch is not engaged.

3. Raise the rollover protection system ROPS/

FOPS until the safety latch (C, Fig. 589) is
engaged.

Fig. 590 - Heater Hoses

5. Install the heater temperature control cable (F,

Fig. 591) and tighten the cable clamp (G, Fig.
591).

Fig. 589 - ROPS/FOPS Safety Latch

4. Install the two coolant hoses (D, Fig. 590) to the

heater assembly. Tighten the hose clamps (E, G
Fig. 590) securely.

Fig. 591 - Heater Temperature Control Cable

50950457/A0719 318 Printed in U.S.A.


6. Disengage the ROPS/FOPS safety latch (H, Fig.
592) and lower the ROPS/FOPS.
Fig. 592 - ROPS/FOPS Safety Latch
7. Install the two capscrews, washers, and nuts
(I, Fig. 593) securing the ROPS/FOPS to
the machine. Tighten the capscrews and nuts
securely.
I K
Fig. 593 - ROPS/FOPS Mounting Hardware
Printed in U.S.A.
Cab
8. Install the heater air filter and the heater access
cover using the 10 capscrews (J, Fig. 594).
Fig. 594 - Heater Filter Access Cover
9. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
10. Start the machine and warm it up to normal
operating temperature.
11. Disengage the lift arm support device (K, Fig.
595) and lower the lift arm (L, Fig. 595).
Fig. 595 - Lift Arm Support Device
12. Turn on the heater system and inspect for proper
operation of the heater modes.
13. Shut off the machine.
319 50950457/A0719
Cab

Instrument Panel Removal/

Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases. B
B

Instrument Panel Removal

1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.
2. Disconnect the negative (-) battery cable at the B
battery, or, if equipped, turn the electrical dis- B
connect switch to OFF. Secure the cable away
from the battery terminals.
NOTE: The use of an assistant may be needed Fig. 597 - Instrument Panel Capscrews
for the removal of the window assembly.
NOTE: Note the location of all electrical connec-
3. Remove the 12 capscrews and nuts (A, Fig.
tors to aid in installation.
596) that secure the right side window assembly
(if equipped) to the rollover protection struc- 6. Tag and disconnect all electrical connectors
ture (ROPS)/falling object protective structure from the instrument panel.
(FOPS).
7. Remove the lower P-clip (C, Fig. 598) that
secures the instrument panel harness to the
instrument panel and remove the instrument
A
panel from the machine.

Fig. 596 - Right Side Window Assembly

4. Remove the right side window assembly from

ROPS/FOPS. Fig. 598 - Instrument Panel P-clip

5. Remove the four capscrews (B, Fig. 597) that

secure the instrument panel to the ROPS/FOPS.

50950457/A0719 320 Printed in U.S.A.


Instrument Panel Installation
1. Install the P-clip (A, Fig. 599) securing the
instrument panel harness to the instrument
panel.
Fig. 599 - Instrument Panel P-clip
2. Connect all electrical connectors to the instru-
ment panel as noted during the removal.
3. Install the instrument panel, securing it to the
rollover protection structure (ROPS)/falling
object protective structure (FOPS) with the four
capscrews (B, Fig. 600).
B
B NOTE: Some machines may vary slightly from
B 1. Complete the “Mandatory Safety Shutdown
B
Fig. 600 - Instrument Panel Capscrews
NOTE: The use of an assistant may be needed
for window assembly installation.
Printed in U.S.A.
Cab
4. Install the right side window assembly (if
equipped), securing it to the ROPS/FOPS with
the 12 capscrews and nuts (C, Fig. 601). Tighten
the nuts securely.
Fig. 601 - Right Side Window Assembly
5. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
6. Turn on the machine and check for proper func-
tion of the instrument panel.
7. Turn off the machine.
Programmed Display Removal/
Installation
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
Programmed Display Removal
Procedure” on page 16.
2. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals..
3. Remove the instrument panel. See “Instrument
Panel Removal” in this section for more
information.
321 50950457/A0719
Cab
4. Disconnect the programmed display electrical
connector (A, Fig. 602).
5. Remove the lock ring (B, Fig. 602) that secures
the programmed display to the instrument panel,
and remove the programmed display from the
machine.
3. Install the instrument panel. See “Instrument
Panel” in this section from more information.
4. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
5. Turn on the machine to check for proper func-
tion of the programmed display.

6. Turn off the machine.

A B

Fig. 602 - Programmed Display Lock Ring

Programmed Display Installation

1. Install the programmed display into the instru-
ment panel and secure it with the lock ring (A,
Fig. 603).
2. Connect the programmed display electrical con-
nector (B, Fig. 603).

B A

Fig. 603 - Programmed Display Lock Ring

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 Cab

Operator Presence Switch

Removal/Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
C

Operator Presence Switch Removal

1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16. B
2. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
NOTE: Operator’s seat removal is necessary for Fig. 605 - Operator Seat Presence Switch
removal of the operator presence switch.
Operator Presence Switch Installation
3. Remove the operator’s seat. See “Operator’s
Seat Removal” in the Mainframe section for 1. Install the operator seat presence switch (A, Fig.
more information. 606) onto the seat frame.
4. Remove the four capscrews (A, Fig. 604) that 2. Connect the operator seat presence switch elec-
secure the operator’s seat to the operator’s seat trical connector (B, Fig. 606).
base.

A A
B

Fig. 606 - Operator Seat Presence Switch

Fig. 604 - Operator’s Seat Base Mounts

5. Disconnect the operator seat presence switch

electrical connector (B, Fig. 605).
6. Remove the operator seat presence switch (C,
Fig. 605) by squeezing the locking tabs and
pushing upwards.

Printed in U.S.A. 323 50950457/A0719

Cab
3. Install the operator’s seat onto the operator’s Restraint Bar Switch Removal/
seat base, securing it with the four capscrews
(C, Fig. 607).
Installation
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.

Restraint Bar Switch Removal

1. Complete the “Mandatory Safety Shutdown
Procedure” on page 16.

C C 2. Disconnect the negative (-) battery cable at the

battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
3. Remove the four clips (A, Fig. 608) and remove
the right side restraint bar switch cover (B, Fig.
608) from the machine.
Fig. 607 - Operator Seat Base Mounts

4. Install the operator’s seat into the machine. See

“Operator’s Seat Installation” in the Mainframe
section for more information.
A
5. Connect the negative (-) battery cable at the bat-
tery, or, if equipped, turn the electrical discon-
nect switch to ON.
B
6. Turn on the machine and check for proper func-
tion of the operator seat presence switch.

7. Turn off the machine.

Fig. 608 - Restraint Bar Cover

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4. Disconnect the restraint bar switch electrical
connector (C, Fig. 609).
Cab
Restraint Bar Switch Installation
1. Install the two-part restraint bar switch (A, Fig.
611), securing it to the machine with the four
capscrews, washers, and nuts (B, Fig. 611).
Tighten the nuts securely.

C A

B
Fig. 609 - Restraint Bar Switch Electrical
Connector A
B
5. Remove the four capscrews, washers, and nuts
(D, Fig. 610) that secure the two-part restraint Fig. 611 - Restraint Bar Switch
bar switch (E, Fig. 610) to the machine.
2. Connect the restraint bar switch electrical con-
nector (C, Fig. 612).

D C

E
D

Fig. 610 - Restraint Bar Switch

6. Remove the restraint bar switch from the Fig. 612 - Restraint Bar Switch Electrical
machine. Connector

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Cab

3. Install the restraint bar switch cover (D, Fig.

613), securing it to the machine with the four
clips (E, Fig. 613).

Fig. 613 - Restrain Bar Cover

4. Connect the negative (-) battery cable at the bat-

tery, or, if equipped, turn the electrical discon-
nect switch to ON.
5. Turn on the machine and check for proper func-
tion of the restraint bar switch.
6. Turn off the machine.

50950457/A0719 326 Printed in U.S.A.

 Chapter 12
LIFT ARM
Introduction
Lift arms and their associated hydraulics are
designed to hold a variety of implements. The
lifting capability of the arms is carefully matched
with the rest of the machine so that the operator
lifts the load, not the machine. This machine uses a
lift-arm design called radial lift. These lift arms are
connected to the machine with a single pin on each
side. The pins allow the bucket to follow an arc as it
rises. As the bucket starts to rise, it first moves out,
away from the machine. After it gets higher than the
height of the mounting pin, it moves in closer to the
machine.

NOTES

Printed in U.S.A. 327 50950457/A0719

Lift Arm

Lift Arm Components

Lift Arm

1 Bushing/Oilite 9 Weldment/Liftarm Stop/RH 15 Fitting/Grease 1/8 PTF

2 Bushing, Oilite 9 Weldment/Liftarm Stop/RH 16 CS 3/8x2-3/4 C5ZY
3 LN CTR 3/8 CBZY 10 Lift Arm Stop, R.H. 17 CB 3/8x1 C5ZY
4 Pin/Klik 10 Lift Arm Stop, R.H. 18 CS 3/8x3 C5ZY
5 Pin 11 Wiper Rod 19 HWHTRS Tap/R 5/16x3/4 CZY
6 Step Support/Weldment 12 Rubber Stop, Door 20 HJN 5/16 C2ZY
7 LN FL CTR 3/8 CFZY 13 Weldment/Liftarm 21 LW 5/16 RZY
8 Pin, Pivot 14 Guide/Hose Wldmnt

Fig. 614 - Lift Arm Components

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 Lift Arm
Attachment Bracket

1 Pin/Spring 3/8x2 7 Adaptor/Rod 13 FW 17/32 ZY

2 HLN INST 1/2 C2ZY 8 Adaptor/Push Rod 14 Washer/Belleville .53
3 Handle, Hitch, L.H. 9 Wdmnt/2 Pin F-A-T 15 Grips
4 Handle,Hitch, R.H. 10 SHCS 1/2x2-3/4 C8 OCG 16 Fitting/Grease 1/8 PTF
5 Spring/Compression 11 Washer/Special 17 CS 3/8x3/4 C5ZY
6 Pin/Bucket Attach 12 Washer 18 CS 1/2x2-1/2 C8ZY

Fig. 615 - Attachment Bracket Components

Printed in U.S.A. 329 50950457/A0719

Lift Arm

Lift Arm Adjustments 1. Lower lift arm and measure any gap between
the stop and lift arm (E, Fig. 616).
Lift Arm Bushing Replacement

ALWAYS wear safety glasses with side shields

when operating the machine or striking metal
against metal. In addition, it is recommended
that a softer (chip-resistant) material be used to
cushion the blow. Failure to heed could lead to
serious injury to eyes or other parts of the body.
E
1. Remove the lift arm from the loader per the
Fig. 616 - Location to measure lift arm stop gap
procedure in this chapter.
NOTE: It will be necessary to add one shim for
2. Use a punch to drive out the four upper lift arm
every 1/8” (3 mm) gap.
bushings, two on each side of the lift arm.
NOTE: Applying heat to the upper lift arm bush- 2. Raise lift arm and engage the lift arm support
ings will release the adhesive and simplify removal. device.

3. Clean inside the opening to provide a smooth
surface for installation of the new bushings.
4. Apply Loctite® 680 or its equivalent to the new
lift arm bushings and press or drive them into
the lift arm.
5. If replacing the bushings in each lower lift arm,
use a punch to drive them out of the lift arm.
Use a long-nosed plier to carefully remove
the rubber wiper rods at the lower attachment
bracket pivot.
6. Install new bushings by pressing them into place
or using a rubber mallet to drive them into the
lift arm.
7. Reinstall the lift arm on the loader per the pro-
cedure in this chapter
3. Remove one capscrew on the lift arm stop
attached to the front of the chassis that needs
adjustment.
4. Install shim(s) behind the rubber stop and secure
with re-secure the stop to the chassis. Use
removable Loctite® 242 or equivalent retaining
compound.
5. Start the engine and lower the lift arm. Verify
gap and repeat procedure as needed.
Lift Arm Support
A falling lift arm could result in severe injury or
death.

Lift Arm Stop Installation and
Adjustment
NOTE: Lift arm stops should be shimmed as
needed to ensure a gap of no more than 1/8” (3
mm) between the stops and the lift arm when the lift
arm is fully lowered.
If the lift arm must be left in the raised position,
BE SURE to properly apply the lift arm support
device.
The operator must not leave the operator’s
position if the lift arm is in the raised position
unless the lift arm support device is properly
applied.

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 Lift Arm

A
A second person on the outside of the machine
is required to assist with applying the lift arm
support. B

Engage Lift Arm Support

1. Empty and remove the attachment.
2. Bring the machine to a complete stop on a level
surface. Fig. 617 - Lift arm support in storage position

3. Raise the lift arm as high as it will go. b. Use the lift control to raise the lift arm until
the lift arm support device drops over the
4. Move the drive controls to the neutral position. end of the lift cylinder and around the lift
5. Shut off the engine. cylinder rod. Slowly lower the lift arm until
the free end of the support device (C, Fig.
618) contacts the top (D) (rod end) of the lift
cylinder.
The lift arm should remain in the raised position
when the engine is stopped. If the lift arm is
observed moving from the raised position, stay
in the operator’s position, lower the lift arm and
exit the machine. Repair the machine before
operating again.
C

6. Move the lift/tilt controls to verify that the con-

trols do not cause the lift arm and/or the attach-
ment hitch plate to move. D
7. Raise the safety bars/arm rests to apply the park-
ing brake and lock out the hydraulic controls. Fig. 618 - Lift Arm Support Applied
8. Stay in the machine sitting in the operator’s
position. A second person, on the outside of the
machine, must:
a. Remove retaining fastener (A, Fig. 617) The lift arm support device must be properly
securing lift arm support (B) in the storage positioned to prevent the lift arm from falling,
which could result in severe injury or death.
position.

9. Shut off the engine and remove the ignition key.

10. Move the lift/tilt controls to verify that the con-
trols do not cause movement of the lift arm and
hitch plate.

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Lift Arm
11. Unfasten the seat belt and raise the safety bars/
armrests. Exit the machine using the hand-holds.
Take the ignition key with you.
Disengage Lift Arm Support
A second person on the outside of the machine
is required to assist with disengaging the lift
arm support.
1. Start the engine and raise the lift arm as high as
it will go.
2. Move the drive controls to the neutral position.
3. Shut off the engine.
4. Move the lift/tilt controls to verify that the con-
trols do not cause movement of the lift arm and
hitch plate.
5. Raise the safety bars/armrests to disable the
hydraulic controls.
6. Stay in the machine in the operator’s position.
A second person, on the outside of the machine,
must:
a. Remove lift arm support (C, Fig. 618) from
the cylinder rod.
7. To store the lift arm support device, remove it
from the lift cylinder rod and return it to its stor-
age location. Secure the support device under
the lift arm with the lock pin (A, Fig. 617).
Lift Arm Removal
NOTE: Some machines may vary slightly from
what is shown in the photographs in this manual.
Procedures are similar, however, in all cases.
NOTE: Label all hoses and note their locations
before disconnecting them to ensure correct
installation.
IMPORTANT: Park the machine where the lift arm
can be supported with a overhead hoist or similar
device.
NOTE: Some loss of hydraulic fluid will occur
when disconnecting hydraulic hoses. Use
50950457/A0719
absorbent mats to catch any dripping fluid when
disconnecting hoses. Cap and plug hydraulic hoses
after disconnecting.
IMPORTANT: Always dispose of hydraulic fluids
according to environmental laws, or take them to a
recycling center for proper disposal. DO NOT pour
fluids onto the ground or down a drain.
1. Complete the Mandatory Safety Shutdown
Procedure. See “Mandatory Safety Shutdown
Procedure” on page 16.
2. Operate controls with the engine off, power on,
to relieve hydraulic pressure.
3. Disconnect the negative (-) battery cable at the
battery, or, if equipped, turn the electrical dis-
connect switch to OFF. Secure the cable away
from the battery terminals.
Always secure the ROPS/FOPS in the tilted
position with pins and spring pins. Never allow
anyone under the ROPS/FOPS if the tilt secur-
ing pins are not in place.
4. Remove the two capscrews, washers, and nuts
(A, Fig. 619) securing the rollover protection
structure (ROPS)/falling object protective struc-
ture (FOPS) (B, Fig. 619) to the machine.
B
A
Fig. 619 - ROPS/FOPS Mounting Hardware
5. Raise the ROPS/FOPS according to “Raising
ROPS/FOPS” on page 55.
332 Printed in U.S.A.
 Lift Arm
6. Remove the lift cylinder front pin retaining 9. Attach an appropriate lifting device (F, Fig. 622)
capscrew and nut (D, Fig. 620). Repeat for the to the front of the lift arm and raise the lift arm
opposite side. to level.

F
D

Fig. 620 - Lift Cylinder Front Pin Retaining

Hardware

7. Remove the lift cylinder front pin (E, Fig. 621). Fig. 622 - Lift Arm Front Lifting Device
Repeat for the opposite side.
10. Support the lift arm with an appropriate support-
ing device (G, Fig. 623).

Fig. 621 - Lift Cylinder Front Pin

G
8. Lower the lift cylinder and support the lift cyl-
inder on the machine. Repeat for the opposite Fig. 623 - Lift Arm Front Supporting Device
side.
11. Drain or apply a vacuum to the hydraulic
system.

Printed in U.S.A. 333 50950457/A0719

Lift Arm
12. Loosen the nut (H, Fig. 624) on the hydraulic
line bracket. Repeat for the opposite side.
Fig. 624 - Lift Arm Hydraulic Line Bracket
13. Tag and disconnect two hydraulic hoses (I, Fig.
625) from the lift arm hydraulic lines. Repeat
for the opposite side.
Fig. 625 - Lift Arm Hydraulic Hoses
14. Turn off the vacuum if applied.
50950457/A0719
15. Remove the retaining capscrew and nut (J, Fig.
626) from the lift arm pin (K, Fig. 626). Repeat
for the opposite side.
Fig. 626 - Lift Arm Pin Retaining Hardware
NOTE: The lift arm weight (without attachment) is
approximately 800 lb. (362 kg).
16. Attach an appropriate lifting device (L, Fig.
627) to the lift arm.
Fig. 627 - Lift Arm Lifting Device
334 Printed in U.S.A.
 Lift Arm
17. Remove the lift arm pin (M, Fig. 628). Repeat a. Install the lift arm pin retaining capscrew
for the opposite side. and nut (B, Fig. 630). Tighten the nuts
securely. Repeat for the opposite side.

Fig. 628 - Lift Arm Pin Fig. 630 - Lift Arm Pin Retaining Hardware
18. With the aid of an assistant, remove the lift arm 3. Support the front of the lift arm with an appro-
from the machine. priate support device (C, Fig. 631).

Lift Arm Installation

NOTE: The lift arm weight (without attachment) is
approximately 800 lb. (362 kg).
1. With the aid of an assistant, install the lift arm
on the machine using an appropriate lifting
device.
2. Install the lift arm pin (A, Fig. 629). Repeat for
the opposite side.
C

Fig. 631 - Lift Arm Front Supporting Device

4. Apply a vacuum to the hydraulic system if

A
applied during removal.

Fig. 629 - Lift Arm Pin

Printed in U.S.A. 335 50950457/A0719

Lift Arm
5. Connect the two lift arm hydraulic hoses (D,
Fig. 632) to the hydraulic lines. Tighten the
hydraulic hoses securely. Repeat for the oppo-
site side.
Fig. 632 - Lift Arm Hydraulic Hoses
6. Turn off the vacuum if applied.
7. Tighten the nut (E, Fig. 633) securely on the
hydraulic line brackets. Repeat for the opposite
side.
Fig. 633 - Lift Arm Hydraulic Line Bracket
8. Fill the hydraulic system or remove the vacuum
equipment if applied.
50950457/A0719
9. Attach an appropriate lifting device (F, Fig. 634)
to the front of the lift arm.
F
Fig. 634 - Lift Arm Front Lifting Device
10. Remove the supporting device from the front of
the lift arm and lower the lift arm.
11. Raise the lift cylinder into position, and install
the front lift cylinder pin (G, Fig. 635). Repeat
for the opposite side.
Fig. 635 - Lift Cylinder Front Pin
336 Printed in U.S.A.

12. Install the lift cylinder pin retaining capscrew
and nut (H, Fig. 636). Tighten the nuts securely.
Repeat for the opposite side.
Fig. 636 - Lift Cylinder Front Pin Retaining
Hardware
13. Disengage the rollover protection structure
(ROPS)/falling object protective structure
(FOPS) safety latch (I, Fig. 637) and lower the
ROPS/FOPS.
I 16. Install the attachment.
Fig. 637 - ROPS/FOPS Safety Latch
Printed in U.S.A.
Lift Arm
14. Install the two capscrews, washers, and nuts
(J, Fig. 638) securing the ROPS/FOPS to the
machine. Tighten the nuts securely.
Fig. 638 - ROPS/FOPS Mounting Hardware
NEVER use your hands to search for hydraulic
fluid leaks. Use a piece of cardboard or paper.
Escaping fluid under pressure can be invisible
and penetrate the skin, causing serious injury.
15. Start the engine and check for proper machine
operation. Inspect for leaks.
17. Stop the engine.
18. Check the hydraulic system fluid level. Add
hydraulic fluid if necessary.
337 50950457/A0719
Lift Arm

50950457/A0719 338 Printed in U.S.A.

 Chapter 13
SPECIFICATIONS

Fluids/Lubricants Types and Capacities

NOTE: Capacities shown are approximate.
Table 16 - Fluids/Lubricants Types and Capacities

Component/Application Type Quantity

Hydraulic Oil Reservoir Tank
Hydraulic System – Total
Final Drives: Motor
Grease Fittings, Lift Arm/Hitch
Battery Terminals
Diesel Fuel Tank (DPF) / (Non-DPF)
Engine Coolant
Radiator Cap Pressure
XPRT™, or Petro Canada HVI60, Mobil DTE 15M or equivalent, which contain anti-rust,
anti-foam and anti-oxidation additives, and conforms to ISO VG46.
30.0 L (8 U.S. gallons)
37.9 L (10 U.S. gallons)
Mobile SHC 680 50 ml ± 5 ml (0.05 - 0.005 qt.)
Lithium-saponified, brand-name multi-purpose
As required
grease MPG-A
SP-B acid-proof grease As required
Tier 4 engines: ULSD1 low sulfur or ultra-low 36 L (9.5 U.S. gallons) (DPF) / 39 L
sulfur, below 15 PPM. (10.3 U.S. gallons) (Non-DPF)
Long life coolant ASTM D4985, D6210 (United
States)
6.62 L (1.75 U.S. gallons)
SAE J814C, J1941, J1034 or J2036
(international)
1 BAR (14 psi)
IMPORTANT: Refer to the Engine
Operator’s Manual for specific engine
oil recommendations.) 5.87 L (6.2 U.S. quarts)
Service Classification: API-CK-4 pre-
ferred; API-CJ-4 SM acceptable

Engine Oil (with filter)

1. Ultra-Low Sulfur Diesel (ULSD) fuel lubricity must have a maximum scar diameter of 0.45 mm, as measured by ASTM D6079 or ISO
12156-1, or a minimum of 3100 grams as measured by ASTM D6078. Contact your fuel supplier for details. Specification 1-D S15 or
2-D S15, ASTM D975.

Printed in U.S.A. 339 50950457/A0719

Specifications

Dimensions

[X]
[Z] [Y]

[W]
[F]

[D]

[C]

[A]

[B]

[E]
[G] [L]
[J]
[K]
[M] [O]
[Q]
[N] [R]
[U] [S]
[I] [P]
[T]
[H]
[V]

Fig. 639 - Dimensions

A Overall Operation Height – Fully Raised 3650 mm (143.7 in.)

B Height to Hinge Pin – Fully Raised 2769 mm (109.0 in.)
C Reach - Fully Raised 673.1 mm (26.5 in.)
D Dump Angle - Fully Raised 38°
E Dump Height - Fully Raised 2134 mm (84.0 in.)
F Maximum Rollback Angle - Fully Raised 102°
G Overall Height – Top of ROPS 1816 mm (71.5 in.)
H Overall Length with Bucket (w/o Counterweight) 2985 mm (117.5 in.)
I Overall Length without Bucket (w/o Counterweight) 2258 mm (88.9 in.)
J Specified Height 1466 mm (57.7 in.)
K Reach at Specified Height 991 mm (39.0 in.)
L Dump Angle at Specified Height 72°
M Maximum Rollback Angle at Ground 32°
N Carry Position 127 mm (5.0 in.)
O Maximum Rollback Angle at Carry Position 32°
P Digging Position 0 mm (0 in.)
Q Departure Angle (w/o Counterweight) 35°
R Ground Clearance 191 mm (7.5 in.)
S Track Gauge 1039 mm (40.9 in.)
T Track Shoe Width 249 mm (9.8 in.)
U Crawler Base 1283 mm (50.5 in.)

50950457/A0719 340 Printed in U.S.A.

 Specifications

V Overall Width (w/o Bucket) 1290 mm (50.8 in.)

W Bucket Width 1372 mm (54.0 in.)
X Clearance Radius – Front (with Bucket) 1854 mm (73.0 in.)
Y Clearance Radius – Front (w/o Bucket) 1168 mm (46.0 in.)
Z Clearance Radius – Rear (w/o Counterweight) 1290 mm (50.8 in.)

Payloads/Capacities
NOTE: Pallet fork load center is the distance from the front face of the forks to the center of mass of the
load.
Table 17 - Payloads and Capacities

Description1 RT105/1050RT
Buckets Weight Rated Operating Capacity
54 in./9.8 ft3 (1372 mm/0.28 m3) 129 kg (285 lbs) 476 kg (1050 lbs.)
60 in./11.0 ft3 (1524 mm/0.31 m3) 138 kg (305 lbs.) 467 kg (1030 lbs.)
61 in./11.6 ft3 (1549 mm/0.33 m3) 140 kg (309 lbs.) 465 kg (1026 lbs.)

Pallet Forks
16 in. (406.4 mm) Forks with Backrest Rating per EN474-3 213 kg (470 lbs.) 319 kg (704 lbs.)
20 in. (508 mm) Forks with Backrest Rating per EN474-3 213 kg (470 lbs.) 299 kg (660 lbs.)
24 in. (609.6 mm) Forks with Backrest Rating per SAE J1197 213 kg (470 lbs.) 280 kg (620 lbs.)
1. Measured on firm and level ground. Equipped with full fluids and 75 kg (165 lbs.) operator.

Weights
Table 18 - Weights

RT105/1050RT
Operating Mass 1
2141 kg (4720 lbs.)
Maximum Permissible Weight3 2617 kg (5770 lbs.)
Shipping Weight2 1928 kg (4250 lbs.)
1. Equipped with standard bucket, driver and full fluids.
2. Without operator and driver; 10% fuel.
3. Operating mass and a full bucket.

Printed in U.S.A. 341 50950457/A0719

Specifications

Coolant Compound Table

Table 19 - Coolant Compound Table

Outside Temperature Water Anti-corrosion agent Antifreeze

Up to °F (°C) % by volume in³/gal (cm³/L) % by Volume % by volume
39 (4) 99 -
14 (- 10) 79 20
-4 (- 20) 65 34
2.6 (10) 1
-13 (- 25) 59 40
-22 (- 30) 55 45
-44 (-42) 50 50

Track Drive
Table 20 - Track Drive

RT105/1050RT
Tractive Effort 1996 kg (4400 lbs)
Parking Brake Spring Applied/Hydraulically Released
Grade-ability 30°
Track Type/Track Rollers/Roller Type Rubber/3/Steel
Ground Pressure .33 Bar (4.8 psi)
Travel Speed 9.6 - 10.4 kph (6.0-6.5 mph)

Engine
Table 21 - Engine

RT105/1050RT
Engine Make Yanmar
Engine Model (DPF) / (Non-DPF) 3TNV88C-KMSV (DPF) / 3TNV88-BKMS (Non-DPF)
Design In-line 3 cylinder, 4-stroke diesel, naturally aspirated
EPA Tier 4, EU Stage 5 (DPF) / EPA Interim Tier 4, EU Stage
Exhaust Emission Compliance (DPF) / Non-DPF)
3A (Non-DPF)
Applied Regulation EPA Tier 4 / EU Stage 5
Displacement 1,64 L (100 in3)
Bore and Stroke 88 x 90 mm
Compression Ratio 19.1:1
26 kW (35 hp) @ 2800 rpm (DPF) / 26 kW (35 hp) @ 2600 rpm
Gross Power (ISO/TR 14396 : SAE J 1995) (DPF) / (Non-DPF
(Non-DPF)
109 Nm (80 ft.-lbs.) @ 1820 rpm (DPF) / 109 Nm (80 ft.-lbs.) @
Peak Torque (DPF) / (Non-DPF)
1200 rpm (Non-DPF)
Low/High Idle (No Load) 1500 / 2830 rpm
Rated - Full Load Speed 2800 rpm

50950457/A0719 342 Printed in U.S.A.

 Specifications

RT105/1050RT
Fuel Injection System Direct Injection with common rail injection system
Fuel Delivery High-pressure common rail
Fuel Filtering In-line filter cartridge with water trap and replaceable element
Firing Order 1-3-4-2-1 (from flywheel end)
Normal Starting Aid Glow Plugs
Cold Starting Aid (Optional) Engine block / Oil pan heater
Lubrication Forced lubrication with trochoid pump
Crankcase Ventilation Closed
Max. Inclined Angle (engine still supplied with oil) 30° in all directions
Cooling System 6,62 L (7 U.S. qts.)
Permissible Coolant Temperature 105° C (221° F)
Thermostat Rating 82° C (180° F)
Fan Ratio (Variable 0-100% w/ 25% step) 09*2:1
Starter - Power 2.3 Kw 912-Volt-DC)
Alternator Voltage / Amperage (DPF) / (Non-DPF) 55 amperes (DPF) / 40 amperes (Non-DPF)
1. Operation above temperature range may result in overheating; operation below temperature range may result in hard-starting.

Hydraulic System
Table 22 - Hydraulic System: General

RT105/1050RT
Hydraulic Self-Leveling Hydraulic self-leveling in raise mode only (optional)
Pump-to-Engine Ratio 1:1
System Pressure Setting 195 bar (2830 psi) @ 2800 rpm

Port Relief Pressures

Boom Lift 241 bar (3500 psi)
Boom Lower 70 bar (1015 psi)
Tilt Rollback 241 bar (3500 psi)

Printed in U.S.A. 343 50950457/A0719

Specifications

Table 23 - Hydraulic System: Drive Hydraulics

RT105/1050RT
Drive Speed 9.6 - 10.4 kph (6.0-6.5 mph)
Hydrostatic Drive Motors
Maximum Working Pressure 400 Bar (5800 psi)
Type Radial Piston
Rated Pressure 420 bar (6091 psi)
Displacement 400 cc (24.4 cu. in.)
Rotating Bi-directional

Table 24 - Hydraulic System: Work Hydraulics

RT105/1050RT
Main Relief Valve Pressure 195 bar (2828 psi)
System Relief Pressure @ Quick Couplers 189.6 Bar (2750 psi)
Total Flow @ 2800 rpm (Theoretical) 55 L/Min (14.5 gpm)

Table 25 - Hydraulic System: Pumps

RT105/1050RT
Auxiliary Hydraulics Pump (Standard)
Type
Displacement 19.7 cc (1.2 cu. in.)
Theoretical Total Flow @ Rates Speed 14.5 GPM (54.9 L/MIN) @ 2800 rpm
Theoretical 100% Hydraulic Operating Power 23.7 HP (17.4 kW)
Travel Drive System Hydraulic Pump
Type Radial piston
Rated Pressure 420 bar (6092 psi)
Displacement 400 cc (24 cu. in.)
Pump to Engine Ratio 1:1
Charge Pressure 16 bar (230 psi)

50950457/A0719 344 Printed in U.S.A.

 Specifications

Table 26 - Hydraulic System: Cylinders

RT105/1050RT
Tilt Cylinders
Type Double-acting piston
Rod/Bore Diameter 31.75 mm / 57.15 mm (1.25 in / 2.25 in)
Stroke Length 386 mm (15.21 in)
Closed Length 597 mm (23.52 in)
Pressure Rating 207 bar (3000 psi)
Lift Cylinders
Type Double-acting piston
Rod/Bore Diameter 31.75 mm / 57.15 mm (1.25 in / 2.25 in)
Stroke Length 662 mm (26.07 in)
Closed Length 879 mm (34.6 in)
Pressure Rating 207 bar )3000 psi)

Table 27 - Hydraulic System: Forces and Cycle Times

RT105/1050RT
Bucket Breakout
Breakout Force (tilt) 1349 kg (2975 lbs)
Breakout Force (lift) 1380 kg (3043 lbs)
Hydraulic Function Time
SAE Raising Time - Lift 3.9 seconds
SAE Lowering Time - Lift 2.7 seconds
Dump Time - Tilt (stop to stop) 2.2 seconds
Rollback Time - Tilt (stop to stop) 1.6 seconds
Total Boom - Cycle Time 8.1 seconds

Table 28 - Electrical System

RT105/1050RT
Glow Plugs Auto
Backup Alarm TYPE B-107 dB(A) 1 pulse/second
Battery
Type Maintenance-free
Volts 12 V
Group Size (BCI) 34
Cold Cranking Amps @ Temperature 800 CCA @ -18° C (0° F)
Minimum Reserve Capacity @ 25A 110 Minutes

Printed in U.S.A. 345 50950457/A0719

Specifications

Sound Power/Pressure Levels

Table 29 - Sound Power/Pressure Levels

RT105/1050RT
Noise Level/Environmental Level (EU Dir. 2000/14/EC) 1
101 db(A)
Operator Ear (EU Dir. 2006/42/EC)2 85 dB(A)

1. Declared sound power level per ISO 6395:2008 with closed cab @ 70% max. engine cooling fan.
2. Declared sound pressure level per ISO 6396:2008 with closed cab @ 70% max. engine cooling fan.

Vibration Levels
Table 30 - Vibration Levels

RT105/1050RT
Whole-Body Vibration (ISO 2631-1)
Mechanical Suspension Seat 0.98 m/s2
Hand-Arm Vibration (ISO 5349-1)
T-Bar 3.92 m/s2
Hand/Foot 4.31 m/s2

50950457/A0719 346 Printed in U.S.A.

 Index Indicator and Operation Symbols 13
Instrument Panel Removal/Installation 320
Introduction
Component Serial Numbers 11
A L
Air Filter Housing Installation 108 Lift Arm Adjustments 330
Air Filter Housing Removal 107 Lift Arm Components 328
Lift Arm Removal 332
B Lift Arm Support 330
Battery Removal 120 Lift/Tilt Control Removal/Installation 301
Light Bulb Replacement 267
C Lubrication
Filter Table 44
Changing Fuel Filter 61
Lubricant Capacities 41
Component Identification 10
Lubrication Points 41
Control Handle Removal/Installation 310
Lubrication Schedule/Intervals 42
Control Locations 269
Control Modules and Connectors 264 M
Coolant Compound Table 342
Crankcase Oil 47 Machine Controls and Operation 9
Crossmember Removal/Installation 294 Machine Model and Serial Number Locations 11
Machine Orientation 9
D MAINTENANCE
Adding Fuel 60
Dimensions 340
Battery 66
E Changing Engine Oil and Filter 57
Changing Hydraulic Oil and Filter 63
Electronic Foot Throttle Removal/Installation 304 Check Engine Mounting Hardware 54
Engine Access Cover 55 Checking Coolant Level 49
Engine Cooling System 49 Checking Engine Oil Level 56
Engine Error Codes 126 Checking Hydraulic Oil Level 62
Engine Fan Installation 116 Cleaning Cooling System 49
Engine Fan Removal 114 DPF Exhaust System Service 59
Engine Installation 94 Draining/Flushing Cooling System 49
Engine Maintenance 54, 71 Electrical System 65
Engine Removal 84 Engine Air Filters 57
Engine Specifications 342 Engine Cooling System 48
Engine Maintenance 54
F Fuel System Maintenance 59
Fan Belt Adjustment 83 Fuses and Relays 66
Fan Shroud Adjustment 83 Hydraulic Hose Maintenance 64
Fan Shroud Installation 112 Hydraulic System Maintenance 62
Fan Shroud Removal 110 Maintenance Interval 52
Floor Plate Removal/Installation 290 Track Maintenance 65
Fluids/Lubricants Types and Capacities 339 Track Replacement 65
Tracks 65
G Travel Motor Front Case Oil 64
Travel Motor Maintenance 64
Grease Fitting Locations 48 Using a Booster Battery (Jump-Starting) 66
Water Separator Inspection/Maintenance 60
H Windshield Washer Reservoir 68
Heater Removal/Installation 315 Maintenance Schedule 52
Hydraulic Hose Maintenance 64 Mandatory Safety Shutdown Procedure 16
Hydraulic Oil Reservoir 46
Hydraulic System Specifications 343 O
Operator Presence Switch Removal/Installation 323
I
Printed in U.S.A. 347 50950457/A0719
P
Payloads/Capacities 341
Pivot Tube Assembly Installation 298
Pivot Tube Assembly Removal/Installation 296
Programmed Display Removal/Installation 321

R
Radiator/Cooler Installation 106
Radiator/Cooler Removal 104
Restraint Bar Removal/Installation 288
ROPS/FOPS Cab 279
ROPS/FOPS/Cab Removal 281
ROPS/FOPS Installation 284

S
Safety 15
Additional Safety Equipment 25
Applications with Load-Handling Devices 20
Battery Hazards 24
Before Starting 16
Crystalline Silica Exposure 25
During Operation 18
Electrical Energy 21
Fire Hazards 24
Maintenance and Service Safety Practices 21
Parking the Machine 21
Schematics
Electrical 213
Hydraulic 213
Seat Removal/Installation 308
Sound Power/Pressure Levels 346
Specifications
Dimensions 340
Hydraulic System 342, 343
Payloads/Capacities 341
Sound Power/Pressure Levels 344
Tracks 342
Vibration Levels 346
Weights 341
Starter Installation 119
Starter Removal 118
Storage 68

T
Track Drive 342
Troubleshooting Guide 124

V
Vibration Levels 346

W
Weights 341

50950457/A0719 348 Printed in U.S.A.

 Torque Specifications
NOTE: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread
forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in Nm (lb.-ft.) unless marked otherwise.
Straight pipe fitting with thread and screwed plug (GE) Non-return valve Identification aid
Thread
Sealing washer Elastic seal O-ring with elastic seal outside Ø
M10X1.0 9 (7) 18 (13) 15 (11) 18 (13) 10 mm (0.4 in.)
M12X1.5 20 (15) 25 (18) 25 (18) 25 (18) 12 mm (0.5 in.)
M14X1.5 35 (26) 45 (33) 26 (35) 35 (26) 14 mm (0.6 in.)
M16X1.5 45 (33) 55 (41) 40 (30) 50 (37) 16 mm (0.6 in.)
M18X1.5 55 (41) 70 (52) 45 (33) 70 (52) 18 mm (0.7 in.)
M22X1.5 65 (48) 125 (92) 60 (44) 125 (92) 22 mm (0.9 in.)
M27X2.0 90 (66) 180 (133) 100 (74) 145 (107) 27 mm (1.0 in.)
M33X2.0 150 (111) 310 (229) 160 (118) 210 (155) 33 mm (1.3 in.)
M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 mm (1.7 in.)
M48X2.0 290 (214) 540 (398) 260 (192) 540 (398) 48 mm (1.9 in.)
G1/8A 9 (7) 13 (18) 15 (11) 18 (13) 9.73 mm (0.4 in.)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 mm (0.5 in.)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 mm (0.7 in.)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 mm (0.8 in.)
G3/4A 90 (66) 180 (133) 100 (74) 140 (103) 26.44 mm (1.0 in.)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 mm (1.3 in.)
G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41.91 mm (1.7 in.)
G1 1/2A 290 (214) 540 (398) 260 (192) 540 (398) 47.80 mm (1.9 in.)

Printed in U.S.A. 349 50950457/A0719

 Hydraulic fittings with various seals (heavy application). All torque values are in Nm (lb.-ft.) unless marked otherwise.
Straight pipe fitting with thread and screwed plug (GE) Non-return valve Identification aid
Thread
Sealing washer Elastic seal O-ring with elastic seal outside Ø
M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 mm (0.5 in.)
M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 mm (0.6 in.)
M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 mm (0.6 in.)
M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 mm (0.7 in.)
M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 20 mm (0.8 in.)
M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 22 mm (0.9 in.)
M27X2.0 90 (66) 180 (133) 170 (125) 135 (100) 27 mm (1.0 in.)
M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 mm (1.3 in.)
M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 mm (1.7 in.)
M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 mm (1.9 in.)
G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 mm (0.5 in.)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 mm (0.7 in.)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 mm (0.8 in.)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 mm (1.0 in.)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 mm (1.3 in.)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 mm (1.7 in.)
G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 mm (1.9 in.)

50950457/A0719 350 Printed in U.S.A.

 With coarse-pitch thread. All torque values are in Nm (lb.-ft.) unless marked otherwise.
Threads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
M5 5.5 (4.1) 8 (6) 10 (7) 5 (4) 7 (5)
M6 10 (7) 14 (10) 17 (13) 8.5 (6.3) 12 (9)
M8 25 (18) 35 (26) 42 (31) 20 (15) 30 (22)
M10 45 (33) 65 (48) 80 (59) 40 (30) 59 (44)
M12 87 (64) 110 (81) 147 (108) 69 (51) 100 (74)
M14 135 (100) 180 (133) 230 (170) 110 (81) 160 (118)
M16 210 (155) 275 (203) 350 (258) 170 (125) 250 (184)
M18 280 (207) 410 (302) 480 (354) 245 (181) 345 (254)
M20 410 (302) 570 (420) 690 (509) 340 (251) 490 (361)
M22 550 (406) 780 (575) 930 (686) 460 (339) 660 (487)
M24 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620)
M27 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922)
M30 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254)

With fine-pitch thread. All torque values are in Nm (lb.-ft.) unless marked otherwise.
Threads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
M8X1.0 25 (18) 37 (27) 32 (43) 22 (16) 32 (24)
M10X1.0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48)
M10X1.25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46)
M12X1.25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81)
M12X1.5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77)
M14X1.5 135 (100) 200 (148) 173 (235) 120 (89) 175 (129)
M16X1.5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195)
M18X1.5 315 (232) 450 (332) 530 (391) 270 (199) 385 (284)
M20X1.5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391)
M22X1.5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524)
M24X2.0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664)
M27X2.0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959)
M30X2.0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364)

Printed in U.S.A. 351 50950457/A0719

For Support and Service, Contact Your Dealer

Manitou Group
One Gehl Way, West Bend, WI 53095-0179 U.S.A.
www.us.manitou.com

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