Usage:
start by:
a) remove radiator and guard *
b) remove batteries and battery box *
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Stop the engine, lower the bucket to the ground, move the control levers backward and forward to release the pressure in the hydraulic system. Slowly loosen the cap to release any pressure in the hydraulic tank. Let the hydraulic and transmission oil become cool before any lines are disconnected or the oil is drained. |
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1. Drain the oil from the hydraulic tank. The capacity of the system is:
- 920-17.5 U.S. gal. (66 litre)930-19.5 U.S. gal. (74 litre)
2. Drain the oil from the transmission and transfer gears. The capacity of the system is 6.75 U.S. gal. (25.5 litre).
3. Remove cover (1) and fender (3) from the hydraulic tank.
4. Remove covers (2) and (4) from the right side of the machine.
5. Remove tube assembly (5) and elbow (6) from the machine.
6. Remove hose assembly (7). Disconnect hose assembly (8) from the hydraulic pump.
7. Disconnect control linkages (9) and (10), air line (12) and electric wires (11) from the transmission.
8. Disconnect air line (13) from the parking brake chamber assembly.
*These operations are in the Engine Disassembly and Assembly section.
9. Lift the cover on the floor plate and remove the nut, bolt (15) and clip that hold the transmission filler tube (14) and oil level gauge (16).
10. Loosen tube assembly (17) from the steering control valve and the bracket that holds it to the frame of the machine.
11. Remove the bolts that hold oil level gauge (16) and the oil filler tube to the transfer gear case. Remove the filler tube and oil level gauge from the operator's station.
12. Disconnect brake lines (19) and (20) from the master cylinders.
13. Remove reservoir (18) from the machine.
14. Disconnect air line (22) from the master cylinder actuators.
15. Remove the bolts that hold the two master cylinders and actuators to bracket (21). Remove the master cylinders as a unit.
16. Disconnect temperature sending unit (24) from the torque converter housing.
17. Remove tube assembly (23) from the torque converter and transfer gear cases.
18. Disconnect water temperature sending unit (25) from the cylinder head.
19. Disconnect tube assembly (27) from the air compressor. Disconnect hose assembly (28) from the air compressor governor.
20. Disconnect engine oil pressure gauge line (26) from the back of the cylinder block.
21. Remove muffler (29) from the exhaust manifold.
22. Remove governor linkage (33) from the machine.
23. Disconnect fuel line (32) and fuel pressure gauge line (31) from the engine.
24. Disconnect electric wire (30) from the starting motor.
25. Disconnect wiring harnesses (34) at the flywheel housing on the left side of the machine.
26. Remove rear universal joint (35) from the machine.
27. Disconnect intermediate drive shaft (36) from the parking brake flange.
28. Fasten tool (A) to the top of the torque converter housing. Fasten tool (B) to the engine, tool (A) and a hoist.
29. Put a floor jack under the transfer gear case. Remove caps (37) from each side of the machine.
30. Remove support assemblies (38) from each side of the transfer gear case.
31. Remove the bolts, washers and nuts (39) from each side of the engine front support.
32. Remove the engine, torque converter, transmission and transfer gears as a unit with tooling (A) and (B). The weight of the unit is 3200 lb. (1440 kg).
Install Engine, Torque Converter, Transmission And Transfer Gears
1. Make sure washer (1) are in position on each side of the main frame before the engine is installed.
2. Fasten tool (A) to the top of the torque converter housing. Fasten tool (B) to a hoist, tool (A) and the front of the engine. Put the engine, torque converter, transmission and transfer gears in position on the machine as a unit.
3. Install the bolts, washers and nuts that hold the engine front support hand tight.
4. Put a floor jack under the transfer gear case for support.
5. Install support assemblies (2) on each side of the transfer gear case.
6. Lift the supports into position in the frame brackets and install the caps and bolts to hold them in position.
7. Remove the floor jack and tooling (A) and (B) from the engine.
8. Tighten the engine front support bolts.
9. Connect intermediate drive shaft (3) to the parking brake flange and tighten the bolts to a torque of 48 ± 8 lb.ft. (64 ± 11 N·m).
10. Put rear universal joint (4) in position between the rear differential and the output flange and tighten the bolts to a torque of 48 ± 8 lb.ft. (64 ± 11 N·m).
11. Connect fuel line (5) and fuel pressure gauge line (7) to the engine.
12. Install governor control linkage.
13. Connect wiring harnesses (8) at the flywheel housing on the left side of the machine.
14. Install muffler (9) on the exhaust manifold.
15. Connect tube assembly (12) to the air compressor. Connect hose assembly (13) to the air compressor governor.
16. Connect oil pressure line (11) to the rear of the cylinder block.
17. Connect water temperature sending unit (10) to the cylinder head.
18. Connect torque converter sending unit (15) to the torque converter housing.
19. Put clean oil on the O-ring seals and install tube assembly (14) to the torque converter housing and transfer gear case.
20. Install the two master cylinders and actuators (16) as a unit on the machine.
21. Connect air line (17) to the master cylinder actuators.
22. Install the brake reservoir and connect the brake lines to the master cylinders.
23. Put clean oil on the O-ring seal for filler tube (18). Install filler tube (18) and oil level gauge (19) as a unit. Be sure the gasket is in position for the oil level gauge before the bolts are tightened.
24. Tighten the tube assembly to the steering control valve and the bolts that hold it to the frame after the oil level gauge is tightened to the transfer gear case.
25. Connect electric wires (23) to the back-up alarm switch.
26. Connect hose assembly to fitting (22) on the transmission.
27. Connect control linkages (20) and (21) to the transmission control levers.
28. Connect the air line to the parking brake chamber assembly.
29. Put clean oil on the O-ring seals and connect hose assemblies (26) and (27) to the hydraulic pump.
30. Put clean oil on the O-ring seals and install tube assembly (24) and elbow (25) as a unit.
31. Install fender (29) and covers (28), (30) and (31) to the right side of the machine.
32. Fill the hydraulic tank and transmission with oil to the correct levels.
end by:
a) install batteries and battery box *
b) install radiator and guard *
c) remove (bleed) the air from the brakes with tool (C) (See HYDRAULIC BRAKE SYSTEM SERVICING in TESTING AND ADJUSTING).
*These operations are in the Engine Disassembly and Assembly section.
Separation Of Engine From Torque Converter, Transmission And Transfer Gears
start by:
a) remove engine, torque converter, transmission and transfer gears
1. Put the front support of the engine on tooling (A) and install wooden blocks under the transfer gear case and torque converter for support.
2. Remove transmission oil cooler inlet line (1) and outlet line (2).
3. Fasten a hoist to the engine.
4. Remove twelve bolts (3) that hold the engine and torque converter together.
5. Remove the engine from the torque converter. The weight of the engine is 1700 lb. (770 kg).
6. Remove O-ring seal (4) from the torque converter housing.
Connection Of Engine To Torque Converter, Transmission And Transfer Gears
1. Put clean oil on O-ring seal (1) and install it on the torque converter housing.
2. Make sure the torque converter, transmission and transfer gears are on wooden blocks in a horizontal position as shown.
3. Fasten a hoist to engine (2) and put it in position. Make sure the teeth of the flywheel are engaged correctly with the teeth of the torque converter.
4. Install the twelve bolts (3) that hold the engine and torque converter together.
5. Install tooling (A) under the engine front support.
6. Put clean oil on the O-ring seals and install the transmission outlet line (5) and inlet line (4).
end by:
a) install engine, torque converter, transmission and transfer gears