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Skylift Mini-Linesman, Manual

The Skylift Mini-Linesman user manual is essential for mastering its advanced features. Download this manual for free on our website. It offers clear instructions and useful tips to ensure safe usage and optimal performance. Access your copy at manualshive.com today and unlock the full potential of your Skylift Mini-Linesman.

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Summary of Contents for Mini-Linesman

Page 1: ...2 PERIODIC INSPECTION LIST r 3 MACHINE COMPONENTS J r 4 V CHASSIS STEERING DRIVE GROUP y 5 ENGINE KUBOTA DIESEL y 6 S HYDRAULICS J r 7 N REMOTE CONTROL DRIVE FUNCTION ONLY y f 8 V TRAILER y 9 WARRANTY J 10 V N J 600312 ...

Page 2: ...r V J r IS V y r V r V y 01 V y 0 V y V y r 00 V y r N o V y ...

Page 3: ...rs c H A R ...

Page 4: ...LE TRAVELING WITH TRACKS RETRACTED TO THE 35 INCH WIDTH BOOM MUST REMAIN IN STOWED POSITION UNTIL OUTRIGGERS ARE DEPLOYED WARNING You may ONLY travel with the unit in high speed when driving it straight The machine must be low speed when making turns Check and grease track tensioner every eight 8 to ten 10 hours of operation Once outriggers are deployed make sure pins to lock socket are correctly ...

Page 5: ...LECTROCUTION HAZARD DEATH OR SERIOUS INJURY WILL RESULT FROM CONTACT WITH THIS MACHINE TRUCK OR TRUCK ATTACHMENTS IF THEY SHOULD BECOME ELECTRICALLY CHARGED KEEP CLEAR OF TRUCK AND LOAD 617894 A DANGER FALLING FROM PLATFORM WILL RESULT IN DEATH OR SERIOUS INJURY PLATFORM PERSONNEL MUST WEAR A BODY HARNESS WITH AN APPROPRIATE LANYARD ATTACHED TO ANCHOR PROVIDED PLATFORM DOORS AND OR CHAINS IF PROVI...

Page 6: ...ions contained in the machine manufacturer s manuals safety signs attached to equipment your employer s work rules and applicable government regulations You are sure the machine is operating properly and has been inspected and maintained in accordance with manufacturer s manuals You are sure that all safety signs guards and other safety features are In place and In proper condition 601427 A DANGER...

Page 7: ...CALS CHECK ROTATION BOLTS WEEKLY DC PUMP ON OFF DC PUMP LIGHT ON INDICATES OUTRIGGERS EXTENDED AND PINNED IN PROPER LOCATION FOR MACHINE OPERATION Qitf Oi ALIGN FAST LOW ALIGN BOOIVI DRIVE CONTROLS CONTROLS ...

Page 8: ...V DECALS GROUNDING LUG PULL OUT E STOP FOR OPERATION DIESEL ONLY DO NOT DRILL HOLES IN BUCKET ...

Page 9: ...REMOVE FOR OPERATION DOWN DOWN FRONT REAR TRACK OUTRIGGER OUTRIGGER EXTENSIONS UP UP DRIVE CAUTION DRIVE nOWN DOWN TRACK REAR FRONT EHENSIONS OUTRIGGER OUTRIGGER UP UP OUTRIGGERS MUST BE PINNED FOR BOOM OPERATION ...

Page 10: ...uH i s afely mariiKtl 1 fc 7i j i k t it IT i s k fe P L l r f i T U t ivt u m v V vj v V r V mm p y 7 y ...

Page 11: ...es Important safety messages on machines safety signs in manuals or elsewhere When you seethis symbol t e alertto the possibility of personal injury or death Followthe instruc tions in the safety message Why Is SAFETY importantto You ACCIDENTS CAUSE INJURY AND DEATH 3 BIG REASONS ACCIDENTSCOSTTIMEANDMONEY ACCIDENTS CAN BE PREVENTED ...

Page 12: ... u goodsafely ina esntaseanas liteMonnalion pnrided htinnraiual iplenient8hespedtic Monn about ynffiradilnelliatis coMied In the flenutetmei s maraalls Oa r infoniBlion wiiidi nay aliect jtssafe prafion of yffiirniKhbn Is contaM HI saf In ItBuance leqi nnfl safetyjBosnms codes local stata poim and fedaajjaiis ndes and rapUons AT1BniONtFY HIDOI r HAVEIHEIIAMH ACTVfl ER 8HANUAL S FOR YOUR PARIKUUHAB...

Page 13: ...ifitrate Whilesoine ofthe Blustrationsappear Inthisrnanual arenthenatiroof carioensr tlQsappi solelyasarneanstoprornoleyouratMntoil text Asn repeatedythrougf Ihbtnanual ManuliuAieieofAerial Dev Council D1X 1 areverysedousabout human lieandhesiicaused unsafepractice RonemberthaiYOUare thekeytosaf Goodsal practioesnotor pioteotyoubute pr aroiflidyou Stu fiis andtheiiBnufBcti maf s foryourspeciilcaer...

Page 14: ...Types of aerial devices ArtioMad Boom Aerial Devices insulatedornon Insulated Devices insultedor non lnsulatsd ...

Page 15: ...types of aerial devices a s ...

Page 16: ...Mg inG u igactualoperationoftMs aerisldevice loMandfeilow iesal iuleaandrfiQuI fortheloyte ADANGER Uwofthistnachtobyanuntrained peisoncanre Ainseverei yor Ml On tf job yoiarK yourcrew iNJStnotuse bugsor akfiho th cnirr atetReea Ai9Qf Cftpipso Qrm ie i medtelffiMnrsganlngvMffornotfwcanaafeiy The oumicrewmsntberiTBistknowtHWto low taihe lowercontrolsand rasoA procedures KHwlianlK UVEb taii 2 RIGHT ...

Page 17: ...pkiedti iBnoesf eleetiic andappa Use insuisM com rnatBwhen requ t ev use noiHnsuM aeria devices near power DonotiaeffiiBedaldevicetollftwp niaAQrpuii cG iBiiessftisspecSfialydesi andialadfv such loads Weary irMted andaleeynwhen1 Ai cnwtnefltoiihen lowiing0 Use Outrimernacb when aniSc ConBmstote wfft cTSw tnerntos fdim UseBtaxn ifs9 pflC8bie Xscussyourwodcpians p to peMhg WearyourInsult haid hat Us...

Page 18: ...orlianKss tai Salely FMaUffi Sai E gog iirbceslWd lfl8Ulat9d Sl98 BS tisiM9 l IMib amis in lilanl 8is Insuredtels WdweailBrgur CtttnCMig Ww lialg isne M donitUiBGlnni 3 AWiUailHQ DoNOTtwsioossclatl6 n kto san vin sifdn6dloii8liair OftNOT 8af iiqilHMea lnEeiaa Mia VVta i ita edffi RistcantsaA nsgvmii iryorM itotmrlnail ffllyoortedlaL ...

Page 19: ...aiyfEte ru8h togeta obdone lat Qvarioad c patlon andBicofioltor ro Dttaeria devicecffii befixed Inadiortperkxlo ire tRit seikHisBjuryord liasadevaslsiiRgefi safetySidtlttsafe d oth enoous your yioifcerstoactsa Do notferceoroversidertdyoursdf beyondyourcapab esbasedontiair andexpeij ence Usethepropertoolforthejobatliand Donotuse txx sande M b th fe8i6nc8pabiiie9 flRSTAO Ptaytt8afB KiHwbo tosini nQn...

Page 20: ...lc dian tl opaiSBiHicapsulesofyouraolaUlsviis Study010 DANGER WAfWDffi end CAUTIONsaMy onyour 8 Udeviceandd DANGBlWARNING GAUTK Iand INFORMATKWnolffilniheopeistai s manual SlWYTICMANUFACIUREirSOreRA RSrSMANU ALBEFOj OPERATraHEffinALOEVRX IF THBSfSNOMANltAtVlinH nEABlALDEVIGE 6Er IESraWITra X YQUSTAnrW0RIC S FTHEREISSOtraHMGINTHEimjALYOUDCm UNDERSTANO ASKYOUR8UPERViSCmTOE m ITTOYOU ATTBnKNbmnoBBlco...

Page 21: ...otsoiiondeviGe Saf cha isacrossdooropertigs ifeqi ig CGI 0l8 GRH oonlrote Inteik ckdevice Barricade orbanterkitsfor oftaljnt uea nsi coituoi Outriggerpads ifapp able Upperand orkmffboomlatches Wam igli Saf ai Guards InsiMdshields covers and mats Back alami RreexIngi her IIrBsipHes tem Ristaklkil G Ot i dlng ppnefit Useth fteverrentovs f Ssoofinectariys Piayft8afB Teieiidvet QfaQtopniteclkm ...

Page 22: ...Safety before operation CheckThe Aerial Device you begin yourwolltday youshould M the liydraulicsy Realty1 tfin syst Ensurelhat r rlubiicafion is p f ...

Page 23: ... oriM F fmtftnMeiaiwpandaBSoutiffilliySn maniMDaolyDiirsalsldwIcs RgbrlopagesSsndll AW umi DIssdfudorhydrailcUtimter pnssuiBCBiiisnelralsBwsliinoreyssaRilcaiBe lou8bvsy IMess M BidMeuffiisr p ssuiennyiKdlievi8l lB UE8B kei4caii ixafdorwoadtD idlsalebutdonotuseyoitr bBnhand 8 WearB me8Wdorsal Si fweyepntKlion K oiyllisdis ije to itmusti astfceSy temmd Miafew hoursiiyadoctor nffli VPSof OMtUDiddigBl...

Page 24: ...ndltnMgMi aS tgiAipam Aiii iisaiKBffid uninglights paitedata Neverpa htraiflc0683 11 bl i ai WGHT KnowTheWoildngAna AWAiafilftl tii inpaVev8bBtB B ffik anaQwlBBdtoseriHfeitil iffdeath Learn belM asnHShaixxA asp ffi8ib 8 CtieGk Dr Exactio ationofffliyoraitK TVc oroth6ri eA UxalkAitfsfopsa l nMifBCt siopeiStcanopefatsGn Potholes Bnoitenaubs OpentDHKihas DfOfH ofoveitiaip SofioQiMfitiof softorhard St...

Page 25: ...efertothesec tiononFireandExplosbnHazarc 10 WRONG Clean Up pBse snoWricaormudintheseareascan cai youto slipandtall Qeanyourtwdts rfexcessmudt efbraget tingonthe machine tiud caband operator s area on the aerial device Secure these Items inthe tool twx orremcwethem from the madiine 10 A WARNING H theaena deviceisInsulated the insulatedportionsoftheaerial device MUSTtw dryandfree ofgrease orOHto mai...

Page 26: ...esuitwith conta from ai power line DANGER DO NOT maneuvermachine orpersonnel inside PI HIBrTED ZONE 12 Allowforswayrdit and pbtfwm movementin calculatingsafe Mnces ASSUME all electrical partsand wiring aieE RGIZED uyessknown other visB Alw fdfcMtState Provindai company work n es and Fetteral OSHA standante PROHIBrrED ZONE ...

Page 27: ...t For Oi rafion 1 PosiBonvehldeonthemoatlei groui buttto equipmentnnfilnotbeopiatedonenfn thanaspem inthemaiiuf iefsopemto manual ffonanIncgne positionthevehicle80thatthe plattewouUt eoper ontheupgrat Bside na sisdilepoadion 2 Setlhebntee 3 U whe8ichod s k o8i sides 4 Enga powersource 5 Settheoutrig rsCif8oequ pp6d U8eoutrl rpads ifgroundissoftLevelthevdiicleas muchaspo Ue t utobserve nieraifactur...

Page 28: ...K yourfaBiKQtBCtlondm UsoyourpenoraliiDiBdiine Be hooM rfyourewial dsvica atdlfimss link andlisten formalfuix Stop ifa maifimclionorenatto Correctorreport imirad bofl eaton fiotfoftin Mm Know yourcl8amr c88 u a n n Ksepyoureetr8af9tndaectao 14 RIGHT n n n n ...

Page 29: ...evice Safety Precautions Never a ow the booms orbjmtabte to enter trsfliclanes with properbarricading Examextremecare especlaiiywithaMa igtibomand orlargeof tiiititat lewhis potatins to block traffic Check the clearance oveitiead Note any obstmcllons Know exactly how much dea ail parts ofyouraer ial device have around eiectric power lines ADANGEfiimmmirnachinesshaflM be used on ornearany powerHne ...

Page 30: ...enecpizedpowsrIm 16 Bavareofstmngarid orgustywindcotv tions Settirakas and chock the wh beforeoperating Mako siff8 the ai Is dear ofafl peisona befbfQ you startoperating As necefisar useasignal personto controltrafiic Keep yourselfand others awayfrom theoutriggers whenth aret ingoperated Always haveouinggersinview when theyare extended and oruseasignal person towatch Always make swe thatyoufollow ...

Page 31: ...ele 8 boom and piaM In transportposition reqi raise ttieoutHggersfdsoeqiQ irti chocks ifiscngagePTO andthendrivettw machine fofward or backwanis as reqi Afterttia machine has been reposiondd engagethe peilclng bfaks chock thewheels and shift transtnbskin controls to n ortogearfor prooperation iiwer the outfiggers end laval the machine 17 WRONG elevofoutriggetv andfront undvfte Mrial piatforni ...

Page 32: ...ole to entertraffic lanes withoutproper t arricading Exercise extreme care e jeciallywith articulatinfl boom and orlargeoffset turntable while rotating Parkto blocktraffic Check the ctearance overhead Note any obstructions Know exactly how much dearance all partsofyouraer ial device have around electric power lines A DANGER NON INSULATE machinesShanm be u dd on ornearany power line Death orseri ou...

Page 33: ...en the untt e working on energizedpowerlines IB Beware ofstrong ar i or gusty wind conditions Settjrakes and chockthe wh beforeoperating Make sura the area Is dearof ell persons before you startoperating As necessary use asi alpersonto control traffic Keep yourselfand others awayfrom the ggers when thay arebeing operated Always h e outriggers In viewwhen they are being extended and or use asignal ...

Page 34: ...ttne Maintain adequatedear lfie wrch cable and irwdated t oom 96C Moisture grease and debris wfll Mttffl insuiat ingvalue rfthese ixinpoiients wNch could resiA inseriousinjisyordeafii AWARNINQ DONOT AidrainholesinInsulated piaforniorpialfDimEnas 19 WRONG ...

Page 35: ...r lines evenwithinsulal machinBs 16 A DANGER Withaninsulatedmachine never approach overhead power lines with any partof your machine urto all local State Provincial company workmles and Federal OSHA required salsty precautions have been taken Use extreme caifca YOU JiRJST ALLOW FOR PiATFORM SWAY ROCIONG AND CREEP AS WEIL AS ELKTRICALUNE SWAYING If possble have power to the lines dsconnected If not...

Page 36: ...dur ir elecfericatstorms 19 m Titmix W WAI Q Yourplatfonn and platform liner dyn the wtich cable a nd iatkboomsectton mustbe ciry dean befpre operating youraerial device on ornear power fines and paratus o 5turs gr and debris 11 defkttheinsulat ing value ofthese component which could result insenoustn uiyordeath WARNING DO NOT drifi drainholesIninsulated platform orplatform liners 19 WRONG Lightni...

Page 37: ...TFORM IF mERE IS PHASE40 PHASE ORPHASE TO ROUND COKTACT SUC CONTACTwiLL CAUSE SEVERE INJURY Ofl DEATH 20 of the boom istn contact with aphase orground and the operator In contact with anofiier phase or ground and contact ismade with any areaofthe boom tip by the operator Contact vrtth energized power Urns canoauseDEATH ...

Page 38: ... faiVDMiiganyeiecMcalsoinc flppioach orentertheve ifltoyou 9mC6 tainttievehteieisNOTeneftf tfthevelik ener tod oryouamnAsure elandonInsulated pffilorbmt usealongInsubtBdpotsiDoper astheQsnyenQ loiisfoontfol fstenitoiBtng the ptaAmdown Dontrf yourseff during atescye ...

Page 39: ...r MovBtooor sfflo ForiinslposBioningof theplatlbRn go lhacontrols AWiyiNIN6 iteiklngtoO irttiDi8W startsandstopsInaeiydBVtoope aljon m canCffiisa tainagingshockloadsand c sethe piallbnnEDaw vioi WI D0sn lassQ n ins vonongpos ion 08exofinaiy cautioustoprovontany0 tromstiikbigor tsnanng WRnhi6oporsingoonvOK oGCuBati tooiSteqi pmsttorothermataysplacedonthe piatato keeptornfroin shiftingcrMt g 22 m 22...

Page 40: ...bfln AeptBftimiaft Afcii keeptKftfBetanSie pUbrmlQoratal8Be 23 WRONG AWANSNfi Keverbeltofftosnttlac pQia volhersttuqturewhMwwidngf plaitam Z4 whSsAsbooms ehaiaiBBdpom AWARMNQ Onno HNeroeiivroB iilt a teRip toiBa i Bieboom mote leach WlimrBi kMBilngorrotafingliwp MonofiinvdinenL Watch outfDTOb abora bskwandtoallskies Snecssaaiy usea signalposononthegroundtogi you na V DontgatiHBigup youdonibeiong ...

Page 41: ... I I 1 Hiiiiiii iiMlilii If III li It y 11 s I 13 3 ...

Page 42: ...a PKtmm cassteandoesiaisfti ioadisreSevel stowingthe Unit 1 68i 8 booin a onbsuppoitsu B 1e efingrnovemefttofttiattiM I SeGirothet Qni s ithesuppoitsp8rn in8buc ns 27 3 RaisefiteouHg fffsoo ppedltoM travelpos 4 Disengage8ie pro 5 Stopiheengine UseiKoperiift igdsviGes ...

Page 43: ...inoiMQd vlVw IwViSA IIM nrftn llMMV IIHr IM II W hAr IMMiiv TlMf ft proUenis leia ngtDthe sul nniter Ifyou have beea BidKifized to do ma itoiK THE MANUFACTURER S SfflViCE AND OPERATOR S MAHALS Studyi ie check charts exanilne tttetetnH and wsn on tf tnacliine lead MalMra gefous isdess poknedpiofffidy 6asure necessaiysid MonnaHQn oorrectkxils and eqiopntent todo Ihe abcorrectly Use inanuiaciiiT s te...

Page 44: ...rapronandlubterglovesM wooden blocl wire rijpeorsharp dged mdai Ofheavy otjecls SafetyshoesmustbewornatanBrnes 30 Safetyglasses g soraface ieldareatwaya need edforeye protedion frorn eiectric arcs fio from flying debfte orloose materialwhen engineisrunning or tool are used Wearaface sN when you disassecn Diespringlo components orwori with batteryaad Wearaheinwtorgog eswithspecial lenseswhenyou waW...

Page 45: ...wpiiseliMqffiRdenoltfilnilim dolitsnalnteiBnceliilHVvntftwtall IMatocbamihesyypateCAI llY withregant foryouiselland ta isons LOWERITEMS DC DROPm 31 AWm KgqjdaardaDnMigconipoMnte Wqi n9 ataipi dni3ifnaia hnA s Mordeathl EB HWS A ffiaonM AWAYmOMAaMOmPARiaDoirt tanjttffiwiSidangliigtbs looseAwes fSigs wl lia Keepp Mfresoldo edsiiM cndd dait eiHlliilomadftiay 3 32 WRONG Pratedfouraaif rith8uproper ...

Page 46: ...ltofflovasu usesedousin ordeaihtDany IIits Movethemach moitQalevel8Uto Stop engine teieasesi hydrauBopessure Atlsffihin cyMrtodsupportstRitsOfMockaD operatedoonipcnenisiftheyiiBisttMInai AWARffiH6 IX NQTDiSCXX ECTHYl COMPONENTSWHENTHEREIS PRESSURE IN THESYSTEM tanect prastis can rastAineenousIr totheexposed unpiQ tectad face M oiher partsofyourbody 33 i 33 WRONG RdlmiBissmi woriifaigmpnssumeoii io...

Page 47: ...mmlttnliaiistfiiinBslimtaareaiiilSisnn l aMM ifp ioi tlimansiiM Sifi iiid 8MSWO ntadooisand oiittfemin o tomllafriiiHteiiBStomadeBiftsensJnetun ning alw wiiikasalMHiam v onepfison hll dMseatwli3etheoler temtlie nBcliiftRenimeaiyffialiorraweMpraite aoc088LWi aw 8H KBgiws8O lollN6 8 eaw gw ofloraxessdaissopaitidinuiatlenlsdK bj andos ilaccessdooisano wi ceitt all 5i cfe 5B iai te 8ndsaWyslpiai8ialns...

Page 48: ...taihe ffiiinsufalBdgapw aoonMB Im oondueSntaaiBoiBiHiBincolvendars tnaitedaslionooiid insulated Test Testll EnvandInaMll 8ecSon 8 ofsfwsgM inlceRguUyiiermAffimMiwislai PsWMiUBanoaTestProo AWAIWiQiWisnhBeiOiorotoanpinnlslielpass iini toNiW clionofi M4nit a4 el9Cttallnsilat lsetiiuStepafin r PeifbnnftinipertnsuiitedtBst ...

Page 49: ...renoltBftBP ooD9onerib inay8 tQrfn n lUfiflgd8BS8e A M IHiKhirtgQTcni ingii Wtienus alwaysbesuretheyaresdaquata sup 36 AWARNING Neverm ooncreleblocksforsi pCft8 1lMycMcoiiap8e6V8nunifdr loa Makesure3 hoistor youusearehgood re ir NeverusejadQV Gi fiked bottortwist ed parts Neverusefrayed twistedorpirtched cables Neveri bentordMed hooks UislaeiiiaidiBltlseareltdy 36 ...

Page 50: ...anceorioesi bfaices UseoniyM fii d recommended tiymaniMrer BeCareful Wii Fluids Under Pressure The hydrai icsystemmay tieunderpressuiBwhenever the ig neIsniinlngand mayholdpressuieevenafter shuldownJnsiaacyimlerrod8upp HtsfnitsOft cylidersandequ mientseoHB before hydiai sy Cyc eaShydr steei andother controlsaftershutdown b refieve stem piesstire When ventingorfSltgthe hydiaullcsystmit om the fiSer...

Page 51: ...tein Reirioveaabashordetiris fnmthe vehicid fiureftaloSyti 7o9ierRarnmab inateiUarennxKredfrom tie nniihe Ghec fuel o3orhydta fUdieake Re X desntteinacitinebefiwyotiopetgla Q9 rfeeaninu DoMtsnfokBwhenusing A 9p b8ow9ie InstiucikinsontiiQBtw maiBMrafsnianua 8 tteypurmeolto Donotuse EitiarKti Is6qi pedwithei pbigoroSier typeofpreheatffl Alwa usea non8antmat iesM whenyoudean p DondusegaMi iesdfiid ot...

Page 52: ...irane clean water thenseekniQcficaiaitent AWAIVfiKQ Lsad acidbatteilss bband eiqiiosMgases arcs spaiks flainss ffiid lightedtobaxoaway Usefias ctnckbaltetyelectrolytelevel Always enginestop Donotchargeabattaiyorjunip tartOteengine3 the tntteiyisfrozen Warn to60 F 1S 0 orthe battery nayexpiodft 41 UsicmwhsnKfridnQtettstes m flm WRONG ...

Page 53: ...dedpf Besumto 6ebaSaslifriHtcNne 880equ Seenttnuftt specMnafv nspe 1i esandwh daOy Donotqwrslewiilow pr Gi daiiia dinsor bofiBor Kits Nevercutormnonthe orrimpa4 TliiscoiAJcauseexplosivBdecofnprBS J iledwffl nlbo DONOTadda Rlonlywithdryni gen properHrtgequlpnent Ke wtieellug nutsfi t toinamilMtyrer reoommendatk Intire pies Isnoimal hiringoperation itshouidNOT be reduced Wttena u tim presaire dosofr...

Page 54: ...safely Repair AWARMN6 use safetycageorcat 6 Air Resetvoir Tank Drain1 KSO equipp i daily In cold weathar iti espedally riportartttutthe airtBnk 9 be drainedatIdkoiKepershift6dsurddrainIs Tire rep a for qualaiM pmoRiw only ...

Page 55: ...ndchflckforleaks Seehydrsutefluid warning pege40 Operate8iGon olstomakesuie tnat isfunction awBigcontrols8ev timestot surecy i char wi8i09 R te niadirnIrieoessaiy After testing shut k wn checktheworkyoupet any missingcotterpins waders hxknuts Recheckail fluid teveistKforer easingnsnii oroperaikin Inspectall partsdut ref rend replaceifGfBckedOf damaged Bccessivelyworn ordaEmag caisejf iyorM anydsii...

Page 56: ... I I 1 I I 1 1 t I I 1 t t I I kiaasi t t c I 3 0 i 0 a tt 0 ...

Page 57: ...FooaMi EcpiipimntManufactures Institute 10S Rk8I Ptaza OAiap inoi9 e06 3710 wi w 6mi org RtikdhUM ...

Page 58: ...c A R ...

Page 59: ...EEL U 0 Nins MAKE SURE BOLTS ARE TIGHT X 10 ROTATION BEARING BOLTS MAKESURE BOLTS AREncarr TORQUETO 159FTXB X 11 LIFT CYLINDER OlEASEFimNO GREASE WITH MOBILHP GREASE X 12 ROTATION BOX CWBASBFITTTNO GREASE WITH MOBO HP GREASE X 13 ROTATION GEAR TBETH GREASE WITH MOBIL HP GREASE X 14 NYLON SHEAVES CHECK FOR SHARP EDGES CUTS X 15 WEAR PADS CHECK FOR WORN LOOSE OR MISSING PADS X 16 FIBEROLASS extensio...

Page 60: ... MOBIL DTE 11 OR ATP WHERE APPLICABm X 2 ENGINE OIL CHECKLEVEL X CHANGEOIL SEE ENGINEMANUAL 3 TIE DOWN HOOKS MAKE SURE BOLTS ARE TIGHT X 4 ALL WHEEL LUG NUTS MAKE SURE BOLTS ARE TIGHT X 5 HYDRAULIC RETURN FILTER REPLACE X 6 OUTRIGGER PIN GREASE FITTINGS GREASE ADEQUATELY 4 PLCS X HYDRAULIC HOSES FirriNGS CHECK FOR LEAKS CRACKS REPAIR LEAKS IMMEDIATELY X ...

Page 61: ...attery is fully charged 4 Inspect towing hookup for secure attachment 5 Loadyourtrailerso that approximately 10 of the trailerstotalweightis on the hitch For light trailers this should be increased to 15 6 Do Not Overload Stay withinyour gross vehicle ratedopacity Consultyour trailer identificationplate 7 Inflate tires according to manufacturer s specifications inspect tires for cuts excessive wea...

Page 62: ...c A r R 3 ...

Page 63: ...V DJS I 16 17 MFO A 5 COMMENTS USED ON SA 53 61 64 nOHWAfV AVD CMHWWW THE NFC M TiOri CONTAMED Pi TKS DPAWINO 5 TVieSOLE PROP0 rr OF s m n ANV fP ODllCTlONMPACrTOB AS A WHOi WrTHCX t Thf W CM or sen MOmA TCO I UrJlE OTHEf WlS SPeCIFCD DMENSIOrJS A9E JCHCS TOllRAr C6S FRACTONAii I a AI4GUIAR MACH 1 ftSfO TWOPlACEC ClMAl sfllO THREEPIACEHC AL 05 DO NOT SCAiC CAAVmO TITLE OUTRIGGER KNUCKLES SIZE B DW...

Page 64: ...SODVCIIOM N PART OP Ai A WHOIE WTTHOUTTHE WMTTlN P9MCUDN O KnF7 S P OHfTEO UNIESS OTHERWISE SPCCinED 0 MEK 06 AI E PI POCS TOlESAfiCES WACTIONAlt 32 ANCU AP MACHS l eaC t2 TWO PiACS DECIMAL 10 THRfgPlACeOeClMAl 05 BLUE OR BLACK DO wot SCALE OftAW 40 TRIE TIER 4 ABOVE SLAB HYDRAULIC TANK SIZE B SCALE 1 8 WEIGHT DWG NO 4160 REV SHEET 6 OF 6 ...

Page 65: ... AS A WHOIE WlfHOiTT 1HE WRffTEK P9MCSI0N O SCW T S H rTEO r UNlfSS OTHERWISE ytCJHCD OlMSNSlOrG ARC tli NCHES TOIERANCCS RAOC Uls 1 32 Ar4GULAR MACHs l 9E 0 f2 two K CE KCWAl fi10 THREE PlACS OK MAL sO BLUE DO NOT SCALE w VJI iai ITTLE TIER 4 ARBORIST FUEL TANK SIZE B DWG NO 5893 REV SCALE 1 6 WEIGHT ISHEETSpn ...

Page 66: ...MATC CONUN 0 J THS CHPAWINO 6 tXS OlE PBOPtnr Of UYLIFT AHrBEPBODUCTONI MPTOI A A WHOIE Vrnr OUt TrC wriTTBH PB MBSOH O SIYin K UNLESS OTHEI VISE SPECIFBDr DUAcr o s A n t i t K m TOiCRANC S WACTIONAlt 1 32 amgiaa MACMt i t v e t2 TWO nAC KCWAl 1OTO THRtEPlACeOICWAl t 05 BLUE 00 NOT iCAlt OfiAWMG TITLE TIER 4 HYD FUEL TANK GAURD SIZE B DWG NO 4596 REV SCALE l 16 weiGHT SHEET 1OfT ...

Page 67: ...PI OOUCTCN IN A T 0 AS A WHOiE WfTHOOT THE WMTTEN BMCilON Of t n0n COPw AMY JAMt KEPE 6 MOMMlCl APflCATON UNl SS OtHEffWiSe SPeClHED DlMENSlOtG ARE M MCHeS rOlWANCCS RAaCrJALt 1 32 ANGULA9 MACHt TBEr s2 TWO PLACE 0 CMAL 010 IHSEEPlACSOeClMAL tXX6 00 NOT SCAlE ORAWNC TITIE SA61 VALVE FRAME ASSEMBLY AND GUARD SIZE B DWG NO 3117SA61 REV SCALE 1 1 jwEIGHT SHEET 1OF 1 ...

Page 68: ...hiOU WITHOUT THE WlhTTEM P9SCSI0N Of SniVT PROH irtO UNLESS OTHERWISE SPCClfieD CUAE eOMS ARE rt TOLERANCES RAOCKAij 1 3 A14GULAR MACHS TfiErO t2 TWO PIACE KCIMAl t0 0 THVEEPlACEOeCMAl X05 BLUE OONOrSCAlCOAAWNO NAME OATE DRAWN CHECtED ENO Am DJS I 16 17 MfO APfR COMMENtSi TITLE TIER 4 ENGINE COVER SIZE DWG NO REV B 3735 SCALE weight SHEET 3 OF 3 ...

Page 69: ... i QDUcnoH n p n ov AS A wHOiLwimcvr wmmK f MKON Of S njFt S fVOHVirCD I T UNUSS OTHtPWlM SP Cl eO DlMBOONS A E r i C TOLERANCES FRAaCNAlt ANGULAR MACHs TftEtO tWOPlACEDeCWAL j lO THREE PLACE DEOMAl t f FLAT BLACK OO NOT SCAi 0lt Wr40 TITLE REAR SKID PLATE SIZE DWG NO REV B 4539 SCALE IwglGHT SHgT2 0F 2 ...

Page 70: ...Y OF SKYUFT ANT EMK2DUCTCH H A T 00 AS A WHOIE wrfHOi T wnntN P9 SON Of StTin 6 MrOHWTEO T L OTHE WISE Sfeora CMUeNSOMS ME NI4CH6 TOieSANCeS ffACIIOrWLt AMCUUR MACHt I frE O 92 IWO PLACE DtCWAl t W THSCEPlACEOeCMAL 095 aAT BLACK 00 CAl DffAWV C TITLE SIZE B OWG NO 5825 REV SCALE jwEIGHT SHgT2 0F 2 ...

Page 71: ...OOCTION H PART 09 AS A WH016 WITHOUT THC WfiPHEN Of KTiirt 6 pvoHBnu uNiess oTHcewisE specifieo OlMEMSlONS ARE IN k h S TOICI AHCES fVACTOtlALS i 32 ANGULAR MACHi T JfNO t2 TWO PUCE 0 CMAL 0 0 n cEPiAceDeciMAL t a BLUE DO NOT SCAll OfiAWMO NAME DATE DRAWN ZHKKiD 6NCAPM DJS 1 16 7 MfC APfR COMMENTS TITLE REAR OUTRIGGER LEG SIZE DWG NO REV B 5811 SCALE WEIGHT SHEET 2OF2 ...

Page 72: ...SOIC P OPE TV OF StVLin ANVREPPODUCTIONNPARTOP A5 A WHOlE WITHOUT tMg WRITTEN P9M SON O B PeCHftfTED UNLESS OTHCmvlSe SPCOFCD CKMeCCG AffE CHU TOlERANCeS PftAOfOKAlt 1 3J AMGUlAR MACHi I StNO i2 TWO PLACE MCWAl iSlO MRCEPIACCDCCIMAL tCOS BLUE OO NOT iCAit DVAWNC i Vjl iai rniE FRONT OUTRIGGER SIZE DWG NO REV B 5815 SCALE 1 I2 WEIGHT SHEETZOf s ...

Page 73: ... PCP90Ducn0H i PAfrr o AS A WHOIE WIIHOCrr TH WVffTEN PEPMUON Of SKVin s OH rrED r UNieSS QTKEPWISE PECrf ED ARE ifJ r CHES TOL6RANC6S FRACTOfUlt 1 32 Af CULAR MACHs I eEND t2 rwO PUCE DECIMAL iO Q tH EPlAC6 0tClMAl t 005 YELLOW DO NOT SCALE DtAWHG TITLE FRONT DROP STOW SIZE DWG NO REV B 5890 SCALE jWEIGHT SHEET2 0f 2 ...

Page 74: ... SKTcrr ANT K OuCTioN fi PArr AS A WHOll WrmOUTTHE WRITTEN P 9 OH O 6 PftO f itO I UNmS OrH f WlS SPCCmCD CMfreOKS A E N W ct i TOlEtANCES RAOCtAlt 1 32 AiXXlUB MACHs 1 I two PlACI D6C1MAI tfllO mns PIAC6 MCIMAI 2X0S YEUOW DO HOt SC4U mE PIVOT STOW SIZE DWG NO REV B 5887 SCALE WBGHT SHEET 3Of ...

Page 75: ...Tftep ooucnoMNPAnoe AS A WHOtC wrrHcinTHE wrrr Of scnrr e n OH irtD UNLESS otneRwist specmeo DlUE StC 4S Airc m NCKS rOlCCANCES RACIONALI V ANGUl f MACH2 tS TWO PlaCC OEClMAl i0 0 THRfEPlACEOeCMAL WOOD DO NOT SCAU 0 AWIMC TITLE OUTRIGGER PAD SIZE DWG NO R V B MEC 470 SCALE WEIGHT SHEET 1Of ...

Page 76: ... OUCTiON 4fA TO ki A WMOiE Wnxx T r x WVITTEN rE i s CN o Kurr s wo fiiD U AES5 OTHEPWM SI C 0 0M94SOHS Al e CHES TOUPANCES fRACnONA1 t V3 AhtGULAR MACH I KtlO s3 two PLACE oeciMAi t io THREE PLACE OeClUAl i iOS RS DO NOT SCAIE DtAWNO TITIE FOOT STEP MINI ARBORIST SIZE DWG NO REV B 4527 SCALE WEIGHT SHEET2 0f 2 ...

Page 77: ...r c H A R 4 ...

Page 78: ...SKYLIFT 90 TRACK UNDERCARRIAGE MANUAL Skylift Inc 3000 Leavitt Road Unit 6 Lorain Ohio 44052 Office 440 960 2100 Fax 440 960 2104 www skyliftus com ...

Page 79: ...Table of Contents SAFETY PRECAUTIONS 1 TECHNICAL INFORMATION MAINTENANCE BILL OF MATERIALS 11 ...

Page 80: ...n its intended usage IMPORTANT Should you find adiscrepancy between the track mounted owner s manual and this document rely on the information supplied by the manufacturer of the machine or consult the factory EVERY TRACK UNIT HAS INHERENT DANGERS ASSOCIATED WITH IT FOR YOUR SAFETY Keep all guards and shields in place Moving parts can crush and dismember Check that all connections and bolts are ti...

Page 81: ... and undercarriage from outside or from above the unit rather than from underneath Escaping hydraulic fluid under pressure can penetrate the skin and cause serious injury Relieve all pressure from the hydraulic system before connecting or disconnecting the lines or making repairs Never make any alterations or modifications to this equipment WARNING NEVER ATTEMPT TO CLEAN OIL OR ADJUST A MACHINE TH...

Page 82: ...itions Rubber tracks should not be used in certain terrains because damage can occur to the lug sides of the tracks Some common and unfavorable terrain conditions are hard surface roads rocky fields stump fields large ruts or holes scrap rebar troughs crowned ridges and along walls or border stones Inspect the work site before beginning operation and remove any of these items when possible If use ...

Page 83: ...k wear by making the same amount of right and left turns the same front to rear wear loading etc Carry only light loads on slopes when required If the machine operation is dozing or similar alternate the work cycle in both directions to equalize the wear and terrain conditions Do not apply down pressure to implements that cause loss of traction and track spinning such as when using a blade to back...

Page 84: ... the track to ride up onto rocks curbs walls or other objects that bend the track edges This will cause the track rubber to shear or crack along the ends of the steel inserts backbone of the track allowing moisture and contaminants to infiltrate the track Eventual chunking off of the rubber will occur and the steel cords will corrode leading to complete failure OPERATING ENVIRONMENTS Temperature T...

Page 85: ...oid deterioration Tracks should be stored on their side Do not lay flat as if it were on a machine unless support has been provided to the inside oifthe track This will prevent crimping in the track which could weaken the steel reinforcing cords and reduce track life Do not bend the track during storage or it may not track properly when installed ...

Page 86: ...er the belt driving lugs causing wear to the rubber track and possible failure Derailing causes track damage Never repair with used or worn components idler sprocket rollers WARNING Loose tracks will allow excessive machine motion resulting in decreased stability during operation LUBRICATION 1 Different OEM brand hydraulic wheel motor drives are used on track unit assemblies but the lubricating pr...

Page 87: ...tensioner ring should be flush with the tensioner mount plate If the engraved tensioner ring is not in the correct location you must adjust tension to prevent damage to the tracks TENSIONER VIEWINGPORT o r NO TENSION ON COMPRESSION SPRING ENGRAVED TENSIONER RING IS NOT EXPOSED NOT PROPERLY TENSIONED ORRECTLY TENSIONED ENGRAVED TENSIONER RING EXPOSED ...

Page 88: ...rotective plug CLEANING Keep driving system cleaned and properly maintained Remove any debris or mud which could interfere with the operation of the machine If mud and debris is allowed in the undercarriageit can plug the spring loaded tensionerpreventing it from relievingstresson the track when travelingover irreguleir surfaces Mud can build up on the trackrollers thereby over tensioning and stre...

Page 89: ...nd the level check port plug b Fill the oil from the oil supply port up to the LEVEL about lOOOcm 3 c Screw the oil supply discharge port plugs and the level check port plug 4 Gear oil amount lOOOcm 3 5 Gear oil change period a First change 200 hours or 2 months b Second and after 1000 hours or 1 year tfghtenmg torque oil supply discharge port plugs 46 51 N m level check port plug 12 18 N m Genera...

Page 90: ...M NO PART NUMBER 1 7750 2 7720 3 7700 4 7725 5 7751 6 BOLT 7 7773 8 7772 DESCRIPTION CENTER TRACK ASSEMBLY RIGHT TRACK ASSEMBLY LEFT TRACK ASSEMBLY EXTEND RETRACT ASSEMBLY CENTER TRACK ASSEMBLY SKID PLATE 5 8 11 UNCBOLT AGGRESSIVE RUBBER TRACK EXTENSION CYLINDER QTY 1 1 1 2 ...

Page 91: ...TUBING 2 11 7722 1X1X9 TENSIONER GUIDE 2 12 7723 1X1X13 TENSIONER GUIDE 2 13 7724 TENSIONER SUPPORT L ANGLE 1 14 7709 TENSIONER SUPPORT PLATE 1 15 7710 TENSIONER SUPPORT RIB 2 16 7711 GUSSET 3 2 17 7712 GUSSET 4 2 18 7713 DRIVE MOTOR MOUNT HOUSING 1 19 5 8 ll UNO BOLT 6 20 5 8 ll UNO NUT 2 21 7715 GREASE RELIEF VALVE GUARD 1 22 7761 TENSIONER MOUNT PLATE GUSSET 1 23 7759 TRACK TENSIONER ASSEMBLY 1...

Page 92: ...8 l 1 UNO BOLT 6 10 5 8 n UNO NUT 2 11 7759 TRACK TENSIONER ASSEMBLY 1 12 7716 OUTSIDE RIGHT PLATE 1 13 7717 RIGHT PLATE 1 14 7718 RIGHT OUTER PLATE 1 15 7704 TRACK GUIDE 1 16 7705 GEAR MOUNT PLATE 1 17 7707 DRIVE MOTOR MOUNT PLATE 1 18 7711 GUSSET 3 2 19 7706 GUSSET 1 2 20 7709 TENSIONER SUPPORT PLATE 1 21 7710 TENSIONER SUPPORT RIB 2 22 7712 GUSSET 4 2 23 7713 DRIVE MOTOR MOUNT HOUSING 1 24 7714...

Page 93: ...CYLINDER BOSS 4 11 7741 SLAB MOUNT PLATE GUSSET 10 12 7742 REAR HYDRAULIC UNE MOUNT PLATE 1 13 7743 FRONT HYDRAULIC LINE MOUNT PLATE 1 14 1 25 BUNG 1 15 1 5 BUNG 1 16 DRAIN BUNG 1 17 DRAIN PLUG 1 18 7744 TUBING SUPPORT GUSSET 19 7746 FLOW DIVIDER MOUNT PLATE 1 20 7747 BOnOM TUBING SUPPORT GUSSET 21 7748 TRACK TANK GASKET 1 22 7749 HYDRAULIC TANK BAFFLE 1 23 7762 EXTEND CYLINDER MOUNT GUSSET 24 776...

Page 94: ...CTION ASSEMBLY ITEM NO PART NO DESCRIPTION QTY 1 7771 SUCTION LINE 1 2 7768 SUCTION FILTER 1 3 CLAMP 1 75 T BOLT CLAMP 2 4 BARB 1 25 NPTBARB FIHING 1 5 ELBOW 1 26 NPT90 ELBOW 1 6 NIPPLE 1 25 NPT4 LONG NIPPLE 1 15 ...

Page 95: ... MOUNT PLATE 1 3 7758 COUNTERSUNK RETAINER PLATE 1 4 COUNTERSUNK 5 8 11 UNO BOLT 1 5 7766 90 TRACK TENSIONER SPRING 1 6 7756 TRACK TENSIONER CYLINDER BODY 1 7 7767 13 INCH IDLER WHEEL W SLIDE BARS 1 8 SOCKET CAP Ml 0X35 BOLT 4 9 7764 1 50 INCH U SEAL 1 10 7765 1 50 WIPER SEAL 1 11 7777 GREASE RELIEF VALVE 1 16 ...

Page 96: ...gf cm 3 Speed Rated speed 2400 min Rotation Direction Clockwise Max speed 2600 min 4 Suction Pressure 0 02 0 04 MPa 0 2 0 4 kgf cm O to ISO VG 32 46 68 Anti Wear hydraulic fluid JX Nippon Oil Energy Corporation Superhyrando Equivalency Oil 6 Oil temp Temp range 20 4 80 C Peak temperature within 100 C 7 Control Constant torque control 3 Others Pump Torque 48 ON m No REVISION DATE BY APPD P ...

Page 97: ...ustof enginespeed 2 Repair or replace 3 Repairor replace 3 Abnormal noise or abnormal vibration Cavitations 1 The level of oil in the tank is low 2 Air in the oil 3 Water in the oil 4 Clog ofsuction filter 5 High suction pressure 6 Damage ofpiston shoe 7 Installationconditionis no good 8 Wrong coupling 1 Replenish a tank with oil 2 Checkpiping Bleed the air in the hydraulic circuit 3 Replace oil 4...

Page 98: ...ANS STANDARD PART AVAIU BLE AS INDIVIDUAL PART DIV B MEANS AVAILABLE AS INDIVIDUAL PART DIV C MEANS AVAILABLE AS KIT NOT AVAILABLE AS INDIVIDUAL PART DIV BLANK MEANS NOT AVAILABLE APPD DATE CHKD K XmiUiA Dec 15 2005 WORKS NO CHKD TOTAL SHEET NACHI FUJIKOSHI CORP BY HEETS JOB NO DOCUMENT N PL PHV4B 003 ...

Page 99: ... Valve Code R S None With Serge Suppressor Relief Valve y ith Shock Less ftelief Vslve v ilhoul Serge Sappressor Rcliet Valve or Shock I 55S Re I i e f VaIve Oplion Code P with dr ing Brake Hone v ithoul Marking Brake C ear Ratio Code A 1 36 33 B 1 47 53 Cede for Hyd Motor DIsPlaceocnl Lo Hi ao le 28 b 7 4 ciiiVrev 29 7 13 3 cn rev 3 2 19 cnVrsv 35 3 21 3 cnVrev 2 32 4 1 ...

Page 100: ... 2 ...

Page 101: ...STWASHRR SNAP RING SPRWrrN table C9 L SEAL KITCREDi CTWti GEAR C9 I vm T30 I3iy SEAL KIT REDUCTION GEAR 0 RING t RING oTm 0 RING NACHl PART No j Q TY FZD 8322 1 02 FZD 8090 1 06 MV55 204037 FZD 8090 1 10 FZD 8090 1 12 FZD 8322 1 13 FZD 8090 1 14 FZD 8090 1 15 FZD 8322 1 16 FZD 8322 1 17 FZD 8090 1 20 FZD 8322 1 23 RA 35 FZD 8144 1 34 GPF 1 8 GPF 1 4 GHB 4 8235 MVH 204037 GHS 500 1 8739 2sei 136 72...

Page 102: ... 220 210 223 219 231 S M ...

Page 103: ...cn 0 3 3 3 ...

Page 104: ...4671 1 26 FZS 2632 27 2 FZD 49 54 1 17 FZS 2817 29 B i FZD 4954 1 20 YB 5 8 PP h7 8X15 TH 10X25 DiV C4 C5 C6 C6 C6 C6 C6 C4 C6 C6 C6 C5 C3 C4 C9 2 C6 C3 C9 2 C9 2 CPT C9 2 C9 2 C9 Z REMARK JIS B 1501 SIZE 5 8 WHEtL motor model OPTION PHV 4B 60 I0 inTMir OTTNrMA PHV 4B 60n P 10 riTHTAMWTO No DESCRIPTION NACHI PART No s Q TY NACHI PART No 1 Q TY DIV REMARK 301 BODY 1 1 1 i 1 C3 302 SPOOL 1 i I C3 30...

Page 105: ... 2 able C4 BODY 2 SUB C4 BODY 2 SUB ASSY MVD 204000 1 Isel MHB 2B 2 4954 isel C4 202 BODY 2 1 1 I 1 U 211 COM PISTON j 224 OIL SEAL i 1 1 1 able C5 SHAFT SUB ASSY C5 SHAFT SUB ASSY MHSH 2B 4954 Msec 1 nlSH 2B 4954 Isel C5 203 221 SHAFT 1 1 1 iT 1 1 BEARING table C6 CYLimif BARREL SUB CG CYLINDER BARREL SUB ASSY MHCB l 2632 isei MllCB 2 2805 Isel C6 204 20S5 c m CYLINDER BARREL 1 1 Valve plate 1 9 ...

Page 106: ...4266 3 10 1 1 PHV 4B 601U P 10 PMV 2B 2917B8 EAH 8645A I PHV 4B 602U I0 29 7 18 3 PMV 2B 2918 EAH 8645A 1 FZD 4658 1 10 2918 1 PHV 4B 602U P 10 PMV 2B 2918B8 EAH 8645A i I PHV 4B 6032 10 34 2 19 1 PMV 2B 3419 EAH 8645A 1 1 FZD 4660 1 10 3419 1 PHV 4B 6032 P l0 PMY 2B 3419B8 EAH 8645A j 1 PHV 4B 604 10 35 3 21 3 PMV 2B 3521 EAH 8645A 1 FZD 4342 I IO 3521 j 1 PHV 4B 604I4 P 10 PMV 2B 3521B8 EAH 8645...

Page 107: ... A MEANS STANDARD PART AVAILABLE AS INDIVIDUAL PART DIV B MEANS AVAILABLE AS INDIVIDUAL PART DIV C MEANS AVAILABLE AS KIT NOT AVAILABLE AS INDIVIDUAL PART DIV BLANK MEANS NOT AVAILABLE APPD DATE CHKD K Xminik Dec 15 2005 WORKS NO CHKD TOTAL SHEET NACHI FUJIKOSHI CORP JOB NO DOCUMENT N PL PHV4B 003 ...

Page 108: ...Valve Code R S None wilh Serge Suppressor Relief Valve v ith Shock Less Rel icf Valve v ilhoul Serge Suppressor Relief Vaive or Shock Uss Re I i c Va Ive Option Code P y ith Pdrong Brake Hone wilhoiit Marking Brake Gear Ralio Code A 1 36 30 B 1 47 33 Cede or Hjd Molor Oisplaceuenl Lo Hi mode 11 28 6 1V 4 cmVrev 2 29 7 13 3 ciaVrev 32 34 2 1 9 csiVrev 4 35 3 21 3 cKiVrsv ...

Page 109: ... 2 ...

Page 110: ...SPRING PIN table C9 I SEAL KIKREDl CTIOH GEAR C9 I TTW 130 i3iy i fgT seal kit REDUCTION GEAR 0 RING OT G o rTng 0 RING NACHI PART No PZD 8322 I 02 FZD 8090 1 06 MV55 204037 FZD 8090 1 10 FZD 8090 1 12 FZD 8322 1 13 FZD 8090 I I4 FZD 8090 1 15 FZD 8322 1 16 FZD 8322 1 17 FZD 8090 1 20 FZD 8322 1 23 RA 35 FZD 8I44 I 34 GPFl 8 GPF 1 4 GHB 4 8235 MVH 204037 TTf 2set 136 72 T 2 1 Iset TO T2y in Isel T...

Page 111: ...m in fn CN CN 4 ...

Page 112: ...en 0 306 3 3 ...

Page 113: ...D 4671 1 26 FZS 2632 27 2 FZD 4954 1 17 FZS 28j7 29 B l FZD 4954 1 20 YB 5 8 PP h7 8Xl5 TH 10X25 DIV REMARK C4 C5 C6 C6 C6 C6 C6 C4 C6 C6 C6 JIS B 1501 SIZE 5 8 C4 C9 2 C6 C3 C9 2 C9 2 C9 2 C9 2 C9 2 C9 2 table 3 BODY I ASSY CROUP WHEtL motor model OPTION PHV 4MO lO rrTHOUrTAlRKTNrBM PHV 4li 60 P wTfiiTAMrrB 10 mm No DESCRIPTION NACHl PART No Q TY NACHl PART No Q TY DIV REMARK 301 BODY I 1 1 1 C3 ...

Page 114: ...raNlSSf pFHOlDBr barM i olMr PIN SPi INC C RETAINER SNAFR NG lable ai 2 SEAL KIT HYDRAULIC MOTOR C9 2 TZ24T 229 Tijai i 3y n w Jinn Yiini SFM KIT HYDRAULIC MOTOR OIL SEAL y rTK ifin NG 0 1 1 m BACK iip idNG HACK lip 1 KG iluKi I iuNii n iiivi PHVHB 604M 10 flTHWTTMmCliRME NACHI PART No MHB 2B EA 8645 MVD 204000 MHSH 2B 4954 MHCB 1 2632 MVS 204000 TTY Iset Tiy Til j 1 2y T2 Ti TO T2 T2y l J2j T 2 T...

Page 115: ...ZD 4266 3 10 1 PHV 4B 601H P I0 PMV 2B 29I7B8 EAH 8645A I PHV 4B 602U 10 29 7 18 3 PMV 2B 2918 EAH 8645A I FZD 4656 I 10 2918 1 i PHV 4B 602U P 10 PMV 2B 2918B8 EAH 8645A 1 PHV 4B 6032 I0 34 2 19 1 PMV 2B 3419 EAH 8645A 1 FZD 4660 1 10 3419 i 1 PHV 4B 6032 P 10 PMV 2B 3419B8 EAH 8645A 1 PHV 4B 604l l0 35 3 21 3 PMV 2B 3521 EAH 8645A 1 FZD 4342 i IO 352l 1 PHV 4B 6041 P 10 PMV 2B 3521B8 EAH 8645A I...

Page 116: ...r NACHi WHEEL MOTOE INSTRUCTIONMANUAL MACHINE MODEL PHV 4B 60 P 10 CUSTOMER APPD DATE 06 7 CHiaD 7 7 CONT NO WORICS NO CHKD TOTAL SHEET 6 SHEETS NACHI FUJIKOSHI CORP BY JOB NO DOCUT n JNT NO ...

Page 117: ...IFICATIONS 5 3 CROSS SECTIONAL DRAWING 6 4 DRAWING OF OPERATIONAL PRINCIPLE 7 5 OPERATION 8 5 1 REDUCTION GEAR SECTION 8 5 2 HYDRAULIC MOTOR SECTION 9 5 3 HYDRAULIC VALVE SECTION 11 5 4 PARKING BRAKE SECTION 12 6 HANDLING 13 6 1 MOUNTING 13 6 2 PIPING 13 6 3 GEAR LUBRICATION OIL 14 6 4 GENERAL PRECAUTIONS 14 ...

Page 118: ...or buying the NACHl products This Instruction Manual is describing the installation driving precautions and the operational principle of the PHV series wheel motors Please read this manual before using the product and keep preciously 1 ...

Page 119: ...ion in which incorrect hanfiling creates the risk of death or serious personal injury A Caution This type of precaution indici ros acondition in which incorrect handling creates Lrf risk of personal injury or raalcrial damage Request This type of precaution indicates a condition in which understanding creates the sar y usage of nsoLor Obeying items are showing tI owing draw rns 0 Mark is prohibiti...

Page 120: ...caution L se ihe suitable hydraulic oil and confirm no overflow and no leakage of hydraulic oil Warning Caution for boreakage oar buDTS t under high paressur Following usage leads the hydraulic equipment breakage or burst and blowing up high pressure oil etc very dangerous situation Don t do absolutely All hydraulic equipraenl are not used exceeding max operating pressure which is designating in t...

Page 121: ...ain the oil to outside By any change the oil drain to outside not to leave it wipe up immediately Discharging the oil to the sewage makes the cause of environment polluiion and fire And dralnins to ihr floor nake s si ijipcry and v ry daniscrous Request Unpacking tendearly The hydraulic equipment is generally heavy and precision parts Taking out from packago lreHt55 carefully and do not hit and dr...

Page 122: ... 5 5 1 1019 4102 PIIV 4e 603 A P ll 1 3 1 34 1 1 2 1 111 1 A U 3 e 125S 1 7M 1 4 01 1 45 71 1 352 3171 1 PHY 4e 6032B P H 6 Jl 47 53 i 2s s m i 1 331 H 1 30S9 1102 1 PKV 4B S04IA P H 1 4 1 35 3 1 1 1 21 3 A 11 36 BOlj 1291 01 113 1 5065 1 iM 1 23t2 317i 1 PHV 4B bD4 8 P lD 8 Jj 47 m1i677 I812 4 1 542 l 151 31 2117 g 410 Rol l U c Ikii wheel lolor within the kereinbelore SPECIFICATION Mole2 Ue here...

Page 123: ...3 CROSS SECTIONAL DRAWING m aj cr 1 n a B Fig 3 3 ...

Page 124: ...NG OF OPERATIONAL PRINCIPLE ai aa Fixed area Rotational area v DRi i r C a r r i e r w Note bl gear 4pcs b2 gear 3pcs Planetary gearbox 2 stages Hydraulic motor Auto kick down valve Counter balance valve Fig 2 ...

Page 125: ... between the gears s2 b2 a2 as a firs I stage speed reducer The reduced output speed of this first stage is reduced again between ihegears si bl al which are connected lo the carrier2 wilh the spline This reduced output speed of he second stage is transmitted lo Ihe body case Rotating parts Ihrough the inner gears al a2 and drives the machine The gear ratio of 2 stage simple planelary speed reduce...

Page 126: ...ic valve the pressurized oil is supplied to Ihe valve plate D When the pressurized oil is suppI ied to the A port Ihls pressurized oi I pushes the piston D in the cylinder barrel D This pushing force is changed to the rotational power by the swash piale 0 and transmitted to the shaft H which is connected lo the cylinder barrel i with the spline The return flow from the cylinder port is going out t...

Page 127: ... lever is changed Ihe pressurized oil is led to the control chamber which is made by the stopper ring and the control cylinder The coniro cylinder moves forward until the I surface of swash plale is in contact with the body 2 and the swash plale angle becomes i3 The motor capacity is made small When an engine is stopped Ihe control chamber is led to the lank port and the swash plate position comes...

Page 128: ...drives the hydraulic molor When ihe pressurized oi 1 is supplied from the B port the hydraulic motor rotates in reverse Even Ihe pressurized oil of the A port is shut off the hydraui ic motor tries lo rotate by inertia force When the pressurized oil from the A port is shut off the spool D tries to return lo left by Ihe spring0 force Al his time the oil in the chamber D tries o go ou to the A port ...

Page 129: ...fixed to the cyl inder barrel D is held between the sleel plale D which are fixed to the body 2 and the body 2 d As a resul I with the fricl ion of these plates Ihe cyl inder barrel and Ihe hydraulic motor are unable to rotate Fig 7 Fig 7 Fig 8 When Aor B ports are pressurized Ihe oi 1 is lead to chamber shown in Fig 8 Then the brake piston CD is moved to the di reel ion shown as arrow Fig 8 again...

Page 130: ...he motor piping Pay attention to the rotating direction and piping 2 When shipped rubber plugs or sleel plugs for drain ports are attached lo the piping ports When piping pay atlenllon as not lo introduce dirt or welding scale into the ports 3 One of two drain ports is used as a drain line Use the upper side port and fill with 100cm of hydraulic oil then connect the piping 4 The permissible drain ...

Page 131: ...rom the oil supply port up to the LEVEL about lOOOcm c Screw the oil supply discharge port plugs and the level check port plug tightening torque oil supply discharge port plugs 46 51 N m level check port plug 12 18 N tn Oil supply port G3 8 Oil level check port Gl 8 Oil d i scharge port G3 8 4 Gear oil amount 1000 cm 5 Gear oi1 change period First change Second and after Fig 10 200 hours or 2 mont...

Page 132: ...ass Kubota engine less than 19kW meets emission standards over the NRTC and also meets the NTE requirements Durable Power The Kubota 05 Series Is an established leader in Its horsepower range and has been the preferred power source of various industrial equipment manufactures EPA TIER D1105 E4B PERFORMANCE CURVE 1600 1800 2000 2200 2400 2600 2800 3000 ENGINE SPEED rpml Clean and Quiet Power o 255 ...

Page 133: ...2 12 40 497 8 19 60 396 0 15 59 608 7 23 96 233 5 9 19 93 0 205 0 Specification Is subject to change without notice Ou ut Gross ntermittent SAE J1995 Oty weight is according to Kubota s standard specification When specification varies theweight wlii vary accordirtgiy KUBOTA ENGINE AMERICA 505 Schelter Road Lincolnshire IL60069 Phone 847 955 2500 Fax 847 955 2501 www l ubotaengine com KUBOTA CANADA...

Page 134: ...or KP 15876 74152 Spacer KP 51601 37670 Temperature Switch MIS CEC SKYLIR HARN Engine Harness 2 MIS 39050 2 Cable Stop 2 KP 15371 11252 Band Muffler 1 CAR AFK102 Ex Flange 3 KP 16271 03450 Cylinder Bolt 1 KP 16616 11620 Air Cleaner Hose 1 CAR nK S5 ET Ex Tube 90 1 TP 50756 Isolator for Radiator Support Bracket 1 LOF 550 1000 35 Tach SRF 68980218 Overflow Hose 1 KTR KTR B1 S5 Drive Flange 1 KTR KTR...

Page 135: ... Rear Legs STN 36691 BP Fuel Filter CAR K05 SLSFB 001 Fuel Filter Brkt CAR nK S5 ER EXH RING KP 15852 52850 Cover Plate KP 1G662 52030 ELEC FUEL PUMP MIS POWERED BY KUBOTA DECAL STN 38564 ONE SHOT KP 800DECAL DECAL ...

Page 136: ...date Date 01 06 2016 Printing Date 13 09 2016 ILLUSTRATED PARTS LIST LISTA DE PIEZAS LISTE DES PIECES MODEL molli D1105 E4B KEA 1 DIESEL ENGINE MOTOR DIESEL MOTEUR DIESEL ubo o 97B98 84410 SEPT SEPTIEMBRE 2013 SEPTEMBRE ...

Page 137: ...0 16241 96010 070 15521 96020 080 17391 96160 090 16271 96160 100 05012 00508 no 05012 00814 120 05012 00610 130 15231 33960 140 16241 33650 150 16241 96262 160 16261 56280 170 16282 96010 180 16271 55350 190 1G896 33610 200 15021 33660 210 16871 73020 COMP CRANKCASE CAP SEALING CAP SEALING PLUG PLUG PLUG PLUG PLUG EXPANSIGN PLUG EXPANSION PIN STRAIGHT PIN STRAIGHT PIN STRAIGHT PIN PIPE PIN PIPE P...

Page 138: ...ng Date 14 09 2016 interchangeable Not Interchangeable Ni New for Old Old for New IBIS 16613 01605 0 005 0 095 0 005 0 025 0 005 0 28 0 011 0 001 01023 50614 16265 96670 13901 33750 6C090 58960 16226 32114 01123 50816 04814 00160 BOLT SEMS DRA PACKING PLUG DRAIN GASKET FILTER OIL BOLT SEMS ORING ...

Page 139: ...EMS 040 1J096 0304Q HEAD CYL COMP 050 15321 96260 CAP SEALING 15261 03370 CAP SEALING 16261 13540 iGUIDE INLET VALVE 080 16261 13560 GUIDE EXHAUST VALVE 090 15281 96010 PLUG 100 16241 03450 BOLT HEADfCYLINDER 110 I1G063 03310 GASKET HEAD CYL mm ...

Page 140: ...T PIPE 050 1J050 36950 SPRING 060 1J050 35132 ICOVERfOIL PUMP 03017 50614 110 I 16264 04132 GASKET GEAR CASE 120 I01023 50645 BOLT SEMS 130 101023 50650 BOLT SEMS HiWilKHaBHa iRimwwii BOLT SEMS BOLT SEMS 160 I 16241 91040 BOLT STUD 180 02751 50060 NUT FLANGE 200 16241 04212 SEAL OIL 230 16245 91540 STUD 240 I16264 83342 COVER GEAR CASE m ...

Page 141: ...070 17331 73342 080 15952 92330 mmm 15951 96660 110 120 16259 05580 130 E9151 33140 140 1J001 96770 ASSY COVER CYL HEAD IGASKET HEAD COVER COMP VALVE BREATHER COVER BREATHER SCREW SEMSfPAN HEAD P PE WATER RETURN NUT CAP PACKING TUBE BREATHER CLAMPHOSE BAND PIPE PLUGfOiL FILLER ORING 1FHZ999 1FJ0001 I 1 010 070 I I New for Old Old for New ...

Page 142: ...KEA 1 ENGINE 000600 OIL FILTER D1105 E4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 5 16615 003 11 Interchangeable Not Interchangeable Nl New for Old Old for New 010 IHH160 32093 ICARTRIDGE OIL FILTER ...

Page 143: ...5 E4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 ouo lJ995 001 n Part Number Part Name IElm S3 020 16282 36500 GAUGE 030 I 048U OQQ9Q 0 RING 040 1G513 36550 PLUG OIL GAUGE 050 I01123 50814 IBOLT SEMS r Interchangeable Nl New for Old Old for New ...

Page 144: ...KET BRG CASE O Ei IIBSfflifflSIlS 1 080 1G679 91020 090 16261 07047 100 16241 04540 105 16292 23483 105 16292 23933 105 16292 23943 no 16241 04560 120 16261 07057 130 16241 04540 140 I16292 23483 16292 23933 140 I16292 23943 BOLT ASSY BRG CASE MAIN BOLTfCASE BRGl METAL CRANKSHAFT METAL CRANKSHAFT METAL CRANKSHAFT BOLT CASE BRG ASSY BRG CASE MAIN iBOLT CASE BRG METAL CRANKSHAFT METAL CRANKSHAFT MET...

Page 145: ...mmtmmmmm 050 16241 060 05712 070 16241 070 1J097 01023 090 16271 100 16271 110 16241 120 16241 16241 24250 GEAR CAM FEATHER KEY STOPPER CAMSHAFT STOPPER CAMSHAFT BOLT SEMS COMP GEAR IDLE BUSH IDLE GEAR COLLAR IDLE GEAR COLLAR IDLE GEAR CIR CLIP IDLE GEAR SHAFT IDLE GEAR BOLT SEMS i 1EKZ999 1EL0001 ...

Page 146: ...040 16241 21330 050 16292 22016 060 1G700 21980 070 16241 22142 080 I16292 22310 16292 22972 16292 22982 090 I1GQ65 23013 110 1A055 24110 120 I16271 95230 16241 23280 1J050 23250 04814 10280 16292 23473 16292 23913 METAL CRANKPIN METAL CRANKPIN COMP CRANKSHAFT GEAR CRANKSHAFT KEY GEAR OIL PUMP DRIVE ISLEEVE CRANKSHAFT COLLARfCRANKSHAFT RING METAL CRANKSHAFT METAL CRANKSHAFT ii STD H 50iiin STD 0 5...

Page 147: ...10 19202 23973 METAL SIDE 210 19202 23983 METAL SIDE 220 220 I1J097 21790 230 I1G993 23765 ImETALXIT ENGINE 230 I1G993 23775 METAL KITrFNGINF Remarks 0 40rnn 0 05 STD 0 01 0 20fmi 0 01 0 40nTn 0 01 STD 0 01 0 20nnt O Ol 0 40fnn 0 01 STD 0 658 0 50niii 0 668 STD 0 325 0 20iiin 0 20iTin 0 32 0 40nin 0 4 nii 0 49 ...

Page 148: ... Printing Date U 09 2016 020 010 16615 009 13 No Part Number Part 010 6692 25013 COMP FLYWHEEL 020 1G081 63820 GEAR RING 03Q 16241 25160 BOLT FLYWHEEL 040 16241 04620 PLATE REAR END 050 15261 91190 BOLT Interchangeable Not Interchangeable Nl New for Old Old for New 1 _j _6 _ 8 ...

Page 149: ...art Name CAMSHAFT FUEL BEARING BALL BEARING BALL GEAR INJEGTION PUMP CAM FUEL BOLT SEMS NUT KEY WOODRUFF STOPPER FUEL C SHAF T Interchangeable Not Interchangeable Nl New for Old Old for New loi 023 50616 BOLT SEMS 16265 55019 16241 55392 16282 55320 16241 55270 16241 55064 16241 55260 19484 55440 16241 55450 16241 55463 16261 97320 ASSY SHAFT GOVERNOR HOLDER GOVERNOR GEAR GEAR GOVERNOR HOLDER GOV ...

Page 150: ...No IPart Number I Part Name 220 16271 55410 CIR CLIP GOV SHAFT 230 I16241 55554 SCREW SET ...

Page 151: ...umber Part Name 010 16285 54093 ASSY APPARATUS IDLE 020 16285 54103 ASSY BOLT ADJUSTiNG 030 15841 92020 NUT 040 15852 92330 NUT CAP 050 15601 96650 PACKING 060 16221 54420 CAP 070 16241 54122 BOLT ADJUSTING 080 1G031 54210 NUTfLOCKl 090 15852 92330 NUT CAP 100 15601 96650 PACKING 110 1G021 96650 GASKET 110 15601 96650 PACKING 120 1G053 54150 BOLT 130 02056 50060 HEX NUT 140 I15601 96650 PACKING 1F...

Page 152: ...E4B KEA 1 ENGINE 020100 STOP SOLENOID D1105 E4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 TTTx IJ 01 030 13 Interchangeable Not Interchangeable Nl New for Old Old for New No Part Number Part Name ...

Page 153: ...20Q SHIM INJECTION 16006 52092 SHIM fNJECTION 16006 52112 SHIMflNJECTlON pump 16006 52122 SHIMnNJECTION PUMP1 1G700 52160 SHIM INJECTION PUMP 16871 91060 BOLT SOCKET HEAD 15841 91500 STUD 15841 92320 NUT CAP 04512 50060 WASHER SPRING LOCK 16030 51320 BOLT JOINT 15841 96650 GASKET 15841 51350 SCREW 15841 96660 GASKET 16030 96010 PLUG 15861 96650 GASKET 0 175 mi 0 200nin 0 250f7in 0 300mii O SSOirm ...

Page 154: ... for Old Old Part Number p 16261 56480 SPRING START 1 16285 56412 SPRING GOVERNOR 1 1G673 56010 ASSY LEVER FORK 1 1G032 56130 LEVER FORK 1 1GQ32 56150 SHAFT FQRK LEVER 1 1G032 56470 SHAFT FORK LEVER 1 16241 56330 BEARING MINIATURIZE 1 16241 56253 COVER FORK ib 4i LEV SHAFT 16299 56260 GASKET 01023 50612 BOLT SEMS 2 16241 56210 COLUR 1 16241 56340 IbEARING MINIATURIZE 1 ...

Page 155: ...16299 57015 PLATE ASSYfCONTROL 16271 57150 LEVER SPEED ib i control 16241 57160 lever SPEED ID 4I t lbU CONTROL 04814 00100 ORING 05411 00420 PIN SPRING 16241 94020 WASHER PLAIN 16241 92020 NUT 16271 56023 COMP LEVER GOVERN OR 16271 57720 LEVER ENGINE STOP 15471 57980 SEAL OIL 16222 57510 SPRING RETURN 16271 57740 SHAFT STOP LEVER 16264 57210 GASKET 01023 50616 BOLT SEIVIS 16245 91540 STUD 02751 5...

Page 156: ...Part Name 220 I 02056 50060 ...

Page 157: ...SCREW BLEATHER 15601 96650 PACKING I 1 15841 42500 ASSY PIPE OVER FLOW 1 15841 42520 PIPE FUEL OVERFLOW 1 14971 42750 CLIP PIPE 2 1G677 53903 KIT HOLDER NQZZLE 3 1G826 92032 NUT 3 15841 53622 GASKET 3_ 19077 53650 SEAL HEAT 16271 53712 PIPE INJECTION 16271 53722 PIPE INJECTION 1_ 16271 53732 PIPE INJECTION _ 15S41 53850 CLAMP PIPE 15841 53860 CLAMP PIPE I 2 03024 50520 SCREW SEMS PAN JSO 1G679 655...

Page 158: ...8510 16032 98520 16032 98530 16032 98540 16032 98550 16032 98560 16032 98570 16032 98580 16032 98590 15841 53622 19077 53650 i SPACER DISTANCE PUSH ROD NUT N0Z2LE WASHER PLAIN PIECE NOZZLE ASSY WASHER ADJUST WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING WASHER ADJUSTING GASKET SEAL HEAT OPTIO...

Page 159: ...30100 FUEL PUMP MECHANICAL D1105 E4B KEA 1 Update Date 01 06 2016 Printing Date U 09 2016 16615 012 21 V sAV v Interchangeable Not Interchanieable Nl New for Old Old for New Part Number i_ Part Natrie ASSY PUMP FUEL NUT FLANGE ...

Page 160: ...D1105 E4B KEA 1 ENGINE 030500 COVER D1105 E4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 O 1J401 040 10 Interc geable No terchangeyie Nl Nw Nct ...

Page 161: ...ARGE WASHER 040 01173 51085 050 04011 50100 060 04512 50100 080 01023 50616 090 16616 13860 no 16229 74280 120 16241 91020 130 16282 97013 140 19B83 65B30 150 19872 65840 160 19872 65880 HEX BOLT WASHER PLAIN WASHER SPRING LOCK BOLT SEMS COVER BELT PULLEY FAN DRIVE BOLTfFAN DRIVE VBELT ASSY COUPLER CONNECTOR CONNECTOR 170 19237 65910 180 19268 65780 190 68271 65920 200 68271 65910 210 19268 65930 ...

Page 162: ...Part Name 230 10010 65830 SuPLER SOLENO 1C010 65880 CONNECTOR ICOl0 65910 IteRMINAL ...

Page 163: ... 64260 130 16652 64780 130 16652 64782 140 16231 64060 150 16231 64230 J60 16241 64650 170 16241 64900 180 16652 64310 190 I15881 64090 Part Name ASSY ALTERNATOR ASSY ALTERNATOR PULLEY DYNAMO NUT COLLAR ROTOR COVER BEARING BEARING BALL WASHER THRUST FRAME ASSY DRIVE END FRAME DRIVE END PLATE RETAINER SCREW ROUND HEAD BOLT THROUGH BRG BAIL BEARING BALL FRAME END COVER END ASSY RECTIFIER BUSH INSULA...

Page 164: ...1 93020 220 15881 93030 230 15881 93040 240 15881 91040 250 15881 92020 260 15881 91050 270 14182 92030 280 1K531 64602 Part Name SPRING BRUSH SCREW ROUND HEAD SCREW ROUND HEAD SCREW ROUND HEAD BOLT NUT BOLT NUT ASSY REGULATOR ...

Page 165: ...Part Number Part Name 010 137560 63010 ASSY STARTER 020 01123 50830 BOLT SEMS I 2 030 021U 50080 HEX NUT 040 I04512 50080 IwASHER SPRING LOCK t2V 1 2kW ...

Page 166: ...63040 070 16285 63030 080 16611 63020 ASSY SWITCH MAGNETIC 090 100 110 I16285 63200 120 11460 63270 130 19212 63100 140 11460 63110 150 19212 97130 160 I 11460 63120 170 11460 93310 180 11460 63320 190 15 m 16285 92010 16611 63450 220 16611 92020 SPRING BRUSH ASSY FRAME END GEAR ROLLER RETAINER BALL ISPRING BOLT Iboltthrough nut hexagon COVER nut hexagon ...

Page 167: ...Part Name l S l 230 15511 96660 ORING 240 16285 63570 PIPE DRAIN n in 250 16611 63660 CORD STOP SOLENOID 260 16612 63100 BAND COVER ...

Page 168: ...Part Nuniber 010 i 15841 39010 ISWITCH OIL 010 I15841 39013 SWITCH OIL 020 I15841 96020 IPLUG ...

Page 169: ...370 IPIPE WATER RETURN 19071 96020 IplUG GASKET WATER FLANGE 01023 50616 BQLT SEMS 01023 50655 BOLT SEMS 16241 73350 PIPE WATER RETURN 1G687 73362 CLAMP HOSE 19434 73014 ASSY THERMOSTAT 16219 73260 COVERfTHERMOSTAT 16221 73270 GASKET THEMOSTAT 01123 50835 BOLT SEMS ...

Page 170: ...IPUMP WATER ASSY 16259 73520 IFLANGE WATER PUMP 1G642 730t 0 ASSY itib4 dUbU SEAL MECHANICAL 16259 73512 J JL ER WATER 15852 73340 IPIPE WATER RETURN 16239 73430 IgASKET WATER PUMP 01023 50630 BOLT SEMS liigMIMgiMaiBOLT SEMS ...

Page 171: ...D1105 E4B KEA 1 ENGINE 050300 WATER PIPE D1105 E4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 rv M I 1Ji01 025 11 Interchangeable Not Interchangeable Nl New for Old Old for New No Part Number ...

Page 172: ...uieigGiiflmuiiSSiv a si LCliLi iL gs iL m IL 010 I 16265 74110 PULLEY FAN 030 I01754 506101bOLT FLANGE ...

Page 173: ... 14350 110 I05411 00428 120 16241 14430 IMP VALVE INLET VALVE EXHAUST SPRING VALVE RETAINER VALVE SP COLLET VALVE SPRING SEAL VALVE STEM CAP VALVE SHAFT ROCKER ARM BOLT FLANGE BRACKET ARM ROCKE R PIN SPRING 130 15841 94022 140 16241 14310 WASHER PLAIN SPRINGfARM ROCKER 160 170 180 16241 14240 190 16241 14410 200 I 1J095 92010 I SCREW ADJUSTING NUT STUD NUT FLANGE ...

Page 174: ... i nterchangeable Not Interchangeable Nl New for Old Old for New rtNumberI Part Name 17407 11770 ASSY MANIFOLD INLET 1 1FMZ999 03 17407 11773 ASSY MANIFOLD INLET 1 1FN000I o R4 16241 05550 JOINT BREATHER PIPE 1 16261 11822 GASKETflN MANIFOLD 1 01754 50616 BOLT FLANGE 3 00 01023 50630 BOLT SEMS 1 01023 50650 IbOLT SEMS I 2 I q q 2 ...

Page 175: ...r 1 Part Name imnmBiRsi uuumaiuij ASSY MANIFOLD INLET ASSY MANIFOLD INLET 020 I16241 05550 JOINT BREATHER PIPE 030 I16261 11822 IgASKETHN MANIFOLD BOLT FLANGE BOLT SEMS 01023 50650 IBOLT SEMS r t 1FMZ999 1FN0001 ...

Page 176: ...4B KEA 1 Update Date 01 06 2016 Printing Date 14 09 2016 oL 16611 028 16 lari Interchangeable Not Interchangeable Nl New for Old Oid for New 010 17213 12312 MANIFOLD EXHAUST 1 020 16261 12350 GASKET EX MANIFOLD 1 030 16241 91490 STUD 040 16271 92010 NUT 6 ...

Page 177: ...PI classification of engine oilaccording to the engine type with internal EGR external EGR or non EGR and the Fuel Type Used Ultra Low Sulfuror High Sulfur Fuels Fuel type Engine oil classification API classification lon EGR Engines with external EGR Engines with non EGR Engines with internal EGR High Sulfur Fuel If the CF 4 CG 4 CH 4 orCI 4 engine oil Isused 0 05 500 ppm vvjth a high sulfur fuel ...

Page 178: ...e and Sulfur Content ppm used must be compliant with all applicable emission regulations for the area inwhich the engine is operated Use of diesel fuel with sulfur content less than 0 10 1000 ppm is strongly recommended If high sulllir el sulfur content 0 50 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fu...

Page 179: ...ed by the fuel system electric fuel pump 2 If an electric fuel pump is not used you must manually actuate the pump by lever to bleed 3 The primary fuel filter 3 must be on the pressure side of the pump if the fuel tank is lower than the injection pump 4 To bleed follow 2 through 5 above PROCEDURE A IMPORTANT Tighten air vent plug of the fuel injection pump except when bleeding or it may stop the e...

Page 180: ...ll the fuel filter keeping out of dust and dirt 5 Air bleed the injection pump IMPORTANT Entrance of dust and dirt can cause a malfunction of the fuel injection pump and the injection nozzle Wash the fuel filter cup periodically 1 O ring 2 Filter element 3 Spring 4 Filter bowl 5 Screw ring CD D Fuel filter cartridge replacement 1 Replace the fuel filtercartridge with a new one every 400 operating ...

Page 181: ...t 3 Take the oil level gauge out again and check the oil level 1ABABAAAP14SA 1 Oil filler plug 2 Oil level gauge Lower end of oil level gauge A Engine oil level within this range is proper PERIODIC SERVICE 15 4 Ifthe oil level is too low remove the oilfillerplug and add new oil to the prescribed level 5 After adding oil wait more than 5 minutes and check the oil level again It takes some time for ...

Page 182: ...he engine before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and cause burns 1 Replace the oil filter cartridge after the initial 50 hours of operation and every 200 hours thereafter 2 Remove the old oilfilter cartridge with a filter wrench 3 Apply a filmof oil to the gasket for the new cartridge 4 Screw in the cartridge by hand When the gasket contacts ...

Page 183: ...eats should occur steam may gush out from the radiator or recovery tank Severe burns could result Checking coolant level adding coolant 1 Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port mm 1 Radiator pressure cap PERIODIC SERVICE 17 2 Ifthe radiator is provided with a recovery tank check the coolant level of the recovery tank Whe...

Page 184: ...e to check radiator hoses and hose clamps periodically If radiator hose is damaged or coolant leaks overheats or severe burns could occur Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months whichever comes first 1 Ifhose clamps are loose or water leaks tighten hose clamp securely 2 Replace hoses and tighten hose clamps securely if radiator hoses are swollen h...

Page 185: ... more specifically also to SAE J814c PERIODIC SERVICE 19 Vol Anti freeze Freezing Point Boiling Point C T c T 50 37 34 108 226 At1 013 X10 Pa 760 mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system 5 Adding the LLC 1 Add only water if the coolant level reduces in the cooling system by evap...

Page 186: ...ust cup optional Remove and clean out the dust cup before it becomes half full with dust usually once a week or even every day ifthe working surroundings are dusty Install the air cleaner dust cup with TOP indicated on the rear of the cup in the up position However it may be installed in either direction when the cover is placed at the lower part IMPORTANT If the dust cup is mounted incorrectly du...

Page 187: ...elt tension Be sure to reinstall the detached safety shield after maintenance or checking Proper fan belt tension A deflection of between 7 to 9 mm 0 28 to 0 35 in when the belt is pressed in the middle of the span 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between the pulleys 3 Iftension is incorrect loosen the alternator mounting bolts and using a lever placed b...

Page 188: ...ritten No water on the pressure cap Since water may freeze when the temperature drops below 0 C 32 l it isvery important that no water is left in the machine 2 Remove dirty engine oil fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts 3 Check all the bolts and nuts and tighten If necessary 4 Remove the battery from the engine adjust the electrolyte l...

Page 189: ...tion pump to eliminate all the air in the fuel system Engine oil becomes thick in cold weather and engine cranks siow Change grade of oil according to the weather temperature Batteiy is discharged and the engine will not crank Charge battery Inwinter always remove battery from machine charge fully and keep indoors Install in machine at time of use IWhen output is insufficient Cause Countermeasures...

Page 190: ...erheated Check the lubricating system Oil lamp lights up during operation Check the lubricating system Check the function of the relieve valve in the lubricating system Check pressure switch Check filter base gasket When engine overheats Cause Countermeasures Engine oil insufTicient Check oil level Replenish oil as required Fan belt broken or elongated Change belt or adjust belt tension Coolant in...

Page 191: ...20 3220 Minimum bare idling speed rpm 1300 900 Order of firing 1 2 3 Direction of rotation Counter clockwise viewed from flywheel side Injection pump Bosch MD Type Mini Pump Injection pressure 13 73 Mpa 140 kgf cm 1991 psi Injection timing Before T D C 20 18 Compression ratio 24 1 Fuel Diesel Fuel No 2 D ASTM D975 Lubricant API classification above CF grade Dimension mm in length width x height 49...

Page 192: ...rder of firing 1 2 3 1 3 4 2 Direction of rotation Counter clockwise viewed from flywheel side Injection pump Bosch MD Type Mini Pump Injection pressure 13 73 Mpa 140 kgf cms 1991 psi Injection timing Before T D C 16 140 Compression ratio 24 1 Fuel Diesel Fuel No 2 D ASTM D975 Lubricant API classification above OF grade Dimension mm in length width height 497 6 X 396 0 x 590 1 19 59 X 15 59x23 2 5...

Page 193: ... EU standard Energize to run 2 CO 03 D lo 05 I r s d 2 5 5E 2 I SOa u o ZZOdlW s ilES SQMraM The parts boxed in are reference NOT equiped for standard engine spec Non marked wire dia is 0 8 1 25 mm WIRING DIAGRAMS 27 ...

Page 194: ...AMS KEA SAE standard Energize to run CO a Y it F Ijlrp y S iKZ oj Q 2 r 5 E 2 2 SOau c The parts boxed in c J are reference NOT equiped for standard engine spec k Non marked wire dia is 0 8 1 25 mm MIgX3I Emms BBMraM ...

Page 195: ...WORKSHOP MANUAL DIESEL ENGINE 05 E4B SERIES 05 E4BG SERIES Kubofo KiSC issued 04 2014 A ...

Page 196: ...sm This section contains infonnation on the structure and the function of the unit Before you continue with the subsequent sections make sure that you read this section Refer to Workshop Manual Code No 9Y021 01870 for the diesel engine mechanism that this workshop manual does not include Servicing This section primarily contains infonnation below Troubleshooting Servicing Specifications Tightening...

Page 197: ... D1005 E4B 3000 rpm specifications type 2 SPECIFICATIONS 1 5 1 8 12 CHECK POINTS OF EVERY 3000 HOURS G 23 4 Fuel System 1 S19 Add BG type 2 SPECIFICATIONS 1 7 4 DIMENSIONS 1 16 1 17 3 MAINTENANCE CHECK LIST G 5 4 CHECK AND MAINTENANCE G 9 G 14 G 23 1 ENGINE BODY 1 M1 2 SERVICING SPECIFICATIONS 1 S5 2 TIGHTENING TORQUES FOR SPECIAL USE SCREWS BOLTS 1 S13 AND NUTS 1 CHECKING AND ADJUSTING 1 S14 KiSC...

Page 198: ...I INFORMATION n KiSC issued 04 2014 A ...

Page 199: ...INFORMATION 1 SAFETY FIRST 2 SPECIFICATIONS 3 PERFORMANCE CURVES 4 DIMENSIONS CONTENTS KiSC issued 04 2014 A ...

Page 200: ...in minor or moderate injury IMPORTANT Indicates that equipment or property damage could result if instructions are not followed NOTE Gives helpful information IBM001A I IBM011A WSMOOOOOIINIOOOIOSI BEFORE YOU START SERVICE Read all instructions and safety instructions in this manual and on your engine safety decals Clean the work area and engine Park the machine on a stable and level ground Let the...

Page 201: ...nnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure Put on an applica...

Page 202: ...ine will operate at elevated idle and hot temperatures for an extended period of time Exhaust gases and exhaust filter components reach temperatures hot enough to burn people or ignite or melt common materials 9Y1210651INI0016US0 PREVENT A FIRE Fuel is very flammable and explosive under some conditions Do not smoke or let flames or sparks in your work area To prevent sparks from an accidental shor...

Page 203: ...SO PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008USO PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher ready at all times Keep the eme...

Page 204: ...govemor Direction of Rotation Counter clockwise viewed from flywheel side Injection Nozzle MiniNozzle DNOPD Injection Timing 0 3142 rad 18 00 before T D C 0 3491 rad 20 00 before T D C 0 3142 rad 18 00 before T D C Firing Order 1 2 3 Injection Pressure 13 73MPa 140 0 kgf cm 1991 psi Compression Ratio 24 1 Lubricating System Forced lubrication by trochoid pump OilPressure Indicating Electrical type...

Page 205: ... Nozzle DNOPD Injection Timing 0 2793 rad 16 00 before TD C 0 2443 rad 14 00 before T D C Firing Order 1 2 3 1 3 4 2 Injection Pressure 13 73MPa 140 0kgf cm2 1991 psi Compression Ratio 24 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter Cartridge type Cooling System Pressurized radiator forced circulat...

Page 206: ...kwise viewed from flywheel side Injection Nozzle Mini Nozzle DNOPD Injection Timing 0 2705 rad 15 50 before TD C 0 2618 rad 15 00 before TD C Firing Order 1 2 3 1 3 4 2 Injection Pressure 13 73MPa 140 0kgf cm 1991 psi Compression Ration 24 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indication Electrical type switch Lubricating Filter Full flow paper filter Cartridge type...

Page 207: ...2 10 y f r J L I I I I I L INFORMATION N m 65 60 55 50 4 g kW h I 270 265 260 J 255 3 1600 1800 2000 2200 2400 2600 2800 3000 3200 min rpm 9Y1210784IEI005US 1 Brake Horsepower 2 Engine Speed 3 B S F C Brake Specific Fuel 4 Torque Consumption 9Y1210784INI0011US0 1 8 KISC issued 04 2014 A ...

Page 208: ...0 r y Nm 65 60 55 50 4 g kW h 270 265 260 255 3 I I I I I I I I I J I I I I I 9Y1210784IEI001US 1600 1800 2000 2200 2400 2600 2800 3000 3200 min rpm 2 1 Brake Horsepower 2 Engine Speed 3 B S F C Brake Specific Fuel 4 Torque Consumption 9Y1210784INI0003US0 1 9 KiSC issued 04 2014 A ...

Page 209: ... Nm 75 70 65 60 4 gfl Wh i270 265 260 3 255 250 9Y1210784IEI002US _J I I I 1 I I I I I I I I I 1600 1800 2000 2200 2400 2600 2800 3000 min rpm 2 1 Brake Horsepower 2 Engine Speed 3 B S F C Brake Specific Fuel 4 Torque Consumption 9Y1210784INI0004US0 1 10 KiSC issued 04 2014 A ...

Page 210: ...RMATION N m i80 75 4 70 65 g kWh 255 250 245 240 3 J I I I I I I I L J I I 1400 1600 1800 9Y1210784IEI003US 1 Brake Horsepower 2 Engine Speed 2000 2 2200 2400 2600 min rpm 3 B S F C Brake Specific Fuel 4 Torque Consumption 9Y1210784INI0005US0 1 11 KISC issued 04 2014 A ...

Page 211: ... i 9Y1210784IEI004US 1 Brake Horsepower J I I L 1300 1500 2 Engine Speed I I I L INFORMATION N m 195 90 4 85 80 g kW h 1255 250 3 245 1700 1900 2 2100 2300 min rpm 3 B S F C Brake Specific Fuel 4 Torque Consumption 9Y1210784INI0006US0 1 12 KiSC Issued 04 2014 A ...

Page 212: ... dia 13 0 in dia 330 mm dia 13 0 in dia D 396 mm 15 6 in 396 mm 15 6 in E 194 mm 7 64 in 194 mm 7 64 in F 602 0 mm 23 70 in 602 0 mm 23 70 in G 233 5 mm 9 193 in 233 5 mm 9 193 in H 200 mm 7 87 in 200 mm 7 87 in 1 250 81 to 251 12 mm dia 9 8744 to 9 8866 in dia 250 81 to 251 12 mm dia 9 8744 to 9 8866 in dia J 56 mm 2 2 in 56 mm 2 2 in 9Y1210784INI0007OS0 1 13 KiSC issued 04 2014 A ...

Page 213: ...IES WSM D1305 E4B D1305 E4B A 497 6 mm 19 59 in B 590 1 mm 23 23 in C 396 0 mm 15 59 in D 185 3 mm 7 295 in E 125 mm dia 4 92 in dia F 222 2 mm dia 8 748 in dia 1 14 INFORMATION 9Y1210784INI0008US0 KiSC issued 04 2014 A ...

Page 214: ...mm 23 28 in B 230 mm 9 06 in C 370 mm dia 14 6 in dia D 396 mm 15 6 in E 194 mm 7 64 in F 607 0 mm 23 90 in 6 238 5 mm 9 390 in H 200 mm 7 87 in 1 250 81 to 251 12 mm dia 9 8744 to 9 8866 in dia J 56 mm 2 2 in 1 15 INFORMATION U 9Y1210784INI0009US0 KiSC issued 04 2014 A ...

Page 215: ...24 16 in D 360 mm 14 2 in 360 mm 14 2 in 360 mm 14 2 in E 333 38 mm dia 13 125 in dia 333 38 mm dia 13 125 in dia 333 38 mm dia 13 125 in dia F 200 02 mm dia 7 8748 in dia 200 02 mm dia 7 8748 in dia 200 02 mm dia 7 8748 in dia G 356 mm dia 14 0 in dia 356 mm dia 14 0 in dia 356 mm dia 14 0 in dia H 290 mm dia 11 4 in dia 290 mm dia 11 4 in dia 290 mm dia 11 4 in dia 1 184 2 mm dia 7 252 in dia 18...

Page 216: ...8 16 UNC 2B Depth 16 mm 0 63 in C 590 1 mm 23 23 in D 360 mm 14 2 In E 333 38 mm dia 13 125 in dia F 200 02 mm dia 7 8748 in dia G 356 mm dia 14 0 in dia H 296 mm dia 11 7 In dia 1 184 2 mm dia 7 252 In dia J 98 mm 3 9 in 1 17 H INFORMATION V CD m 9Y1210784INI0013US0 KiSC Issued 04 2014 A ...

Page 217: ...G GENERAL KiSC issued 04 2014 A ...

Page 218: ... CHECK POINT OF EVERY 50 HOURS G 11 4 CHECK POINTS OF EVERY 100 HOURS G 12 5 CHECK POINTS OF EVERY 200 HOURS G 14 6 CHECK POINTS OF EVERY 400 HOURS G 16 7 CHECK POINTS OF EVERY 500 HOURS G 17 8 CHECK POINTS OF EVERY 1 OR 2 MONTHS G 19 9 CHECK POINT OF EVERY YEAR G 20 10 CHECK POINT OF EVERY 800 HOURS G 21 11 CHECK POINTS OF EVERY 1500 HOURS G 22 12 CHECK POINTS OF EVERY 3000 HOURS G 23 13 CHECK PO...

Page 219: ...el number It shows the month and year of manufacture as below Engine Series Number Series Number Series 1 05 Series Include WG 5 Air Cooled Gasoline 2 V3 Series 6 GZ OC AC EAandE Series 3 08 Series 7 03 Series 4 SM Series Include WG 8 07 Series Year of manufacture Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2008 L 2020 7 2...

Page 220: ...Z999 July N0001 N9999 P0001 PZ999 August Q0001 Q9999 R0001 RZ999 September S0001 S9999 TOOOl TZ999 October U0D01 U9999 V0001 VZ999 November W0001 W9999 X0001 XZ999 December Y0001 Y9999 Z0001 ZZ999 Alphabetical letters 1 and O are not used a b c d e e g D1105 1 D LA0Q1 a Engine Model Name D1105 b Engine Series 1 indicates 05 Series c Year D indicates 2013 d Month L or M indicates June e Lot Number ...

Page 221: ... the original E4B design and EPA or other applicable regulations Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Infonnation E4B engines are identified with EF at the end of the Model designation on the US EPA label Please note E4B is not marked on the engine 1 EMISSION CONTROL INFjORMATION THIS ENGINE MEETS 2013Tier4 afiSS...

Page 222: ...ways disconnect the ground cable from the battery first Remove oil and dirt from parts before you measure Use only KUBOTA genuine parts for replacement to keep the machine perfomiance and to make sure of safety You must replace the gaskets and 0 rings when you assemble again Apply grease 1 to new 0 rings or oil seals before you assemble When you assemble the external or internal snap rings make su...

Page 223: ... and clamp bands Checking intake air line Replacing fuel filter cartridge Cleaning water jacket and radiator interior Replacing fan belt Recharging battery Replacing air cleaner element Checking valve clearance Checking injection nozzle pressure Checking injection pump Checking injection timing Changing radiator coolant L L C Replacing radiator hoses and clamp bands Replacing fuel hoses and clamps...

Page 224: ...assification engine oil with a high Total Base Number a minimum TBN of 10 is recommended Fuel Cetane Rating The minimum recommended Fuel Cetane Rating is 45 A cetane rating greater than SO is preferred especially for ambient temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Diesel Fuel Specification Type and Sulfur Content ppm used must be compliant with all applicable emission regula...

Page 225: ...r or viscosity from the previous drain old oil Never mix two different types of oil NOTE Be sure to inspect the engine locating it on a horizontal place If placed on gradients accurately oil quantity may not be measured Be sure to keep the oil level between upper and lower limits of the dipstick Too much oil may cause a drop in output or excessive blow by gas On the closed breather type engine in ...

Page 226: ... coolant brand cannot be identified drain out all of the remaining coolant and refill with a totally new brand of coolant mix CAUTION Do not remove the radiator cap until coolant temperature is below its boiling point Then loosen the cap slightly to relieve any excess pressure before removing the cap completely IMPORTANT During filling the coolant air must be vented from the engine coolant passage...

Page 227: ...gine oil should have properties of API classification See page G 6 Use the proper SAE Engine Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one Above 25 C 77 T SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 T to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAEIOWor SAE 10W 30 SAE 10W 40 Models Oil Pan Depth 110 mm 4 33 in 125 mm 4 92 in 130 mm...

Page 228: ...d Over tightening may cause defonnation of rubber gasket 4 After the new cartridge has been replaced the engine oil nonnally decrease a little Thus see that the engine oil does not leak through the seal and be sure to read the oil level on the dipstick Then replenish the engine oil up to the specified level IMPORTANT To prevent serious damage to the engine replacement element must be highly effici...

Page 229: ...nge prescribed above When bleeding fuel system 1 Fill the tank with fuel and open the fuel valve 4 2 Loosen the air vent plug 3 of the fuel filter a few turns 3 Screw back the plug when bubbles do not come up any more 4 Open the air vent valve on top of the fuel injection pump 5 Ifequipped electrical fuel feed pump turn the key to AC position and pump the fuel up for 10 to 15 seconds If equipped m...

Page 230: ...nside with kerosene 3 Take out the element 4 and dip it in the kerosene to rinse 4 After cleaning reassemble the fuel filter keeping out dust and dirt 5 Bleed the fuel system IMPORTANT If dust and dirt enter the fuel the fuel injection pump and injection nozzle will wear quickly To prevent this be sure to clean the fuel filter cup 5 periodically 1 Fuel Valve Body 2 Air Vent Plug 3 Fuel Valve Fan B...

Page 231: ...t is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it A Good B Bad 9yi210784GEG0015USO Checking Battery Electrolyte Level 1 Check the battery electrolyte level 2 If the level is below than lower level line 2 and the distilled water to pour level of each cell 1 upper Level Line 2 Lower Level Line 9Y1210784GEG0016USO KiSC issued ...

Page 232: ...gine oil should have properties of API classification See page G 6 Use the proper SAE Engine Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 T SAEIOWor SAE 10W 30 SAE 10W 40 Models Oil Pan Depth 110 mm 4 33 In 125 mm 4 92 in 130 mm...

Page 233: ...ivalent 9Y1210784GEG0010OS0 Checl ing Radiator Hoses and Clamp Bands 1 Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months whichever comes first 2 If the clamp is loose apply oil to the threads and retighten it securely 3 The water hose is made of rubber and tens to age It must be replaced every two years Also replace the clamp and tighten it secu...

Page 234: ...TA genuine filter or its equivalent 9Y1210784GEG0050US0 Replacing Fuel Filter Cartridge Cartridge Tvpe Water and dust in fuel are collected in the filter cartridge So change the filter cartridge every 400 hours service 1 Remove the used filter cartridge with filter wrench 2 Apply a thin film of fuel to the surface of new filter cartridge gasket before screwing on 3 Then tighten enough by hand 4 Lo...

Page 235: ...lushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely Fillwith coolant up to FULL A mark on the recovery tank 3 Start and operate the engine for few minutes Stop the engine and let cool Check coolant level of radiator and recovery tank 3 and add coolant if necessary IMPORTANT Do not start engine without coolant Use clean fr...

Page 236: ...t in the cooling system to get a higher boiling point NOTE The above data is the industrial standards that shows the minimum glycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep the anti freeze mixing ratio less than 50 If there is a leakage add anti freeze and clean soft water in the specified mixing rat...

Page 237: ...e slightly lower than the specified level to prevent overflow 2 Connect the battery to the charging unit following the manufacture s instructions 3 As the electrolyte generates gas while charging remove all port caps 4 The electrolyte temperature must not exceed 40 C 104 F during charging Ifit exceed 40 C 104 F decrease the charging amperage or stop charging for a while 5 When charging several bat...

Page 238: ...ature increases by 1 F increases by 0 0007 when temperature decreases by 1 C increases by 0 0004 when temperature decreases by 1 F Thus if you refer to 20 C 68 F correct the specific gravity reading by the formula below Specific gravity at 20 C Measured value 0 0007 electrolyte temperature 20 C Specific gravity at 68 F Measured value 0 0004 x electrolyte temperature 68 F Specific Gravity 1 260 Sp ...

Page 239: ... the 1TC mark 1 on the flywheel and alignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge 7 If the clearance is not within the factory specifications adjust with the adjusting screw Adjustable Cylinder Location of Piston 3 cylinder 4 cylinder IN EX IN EX When No 1 piston is at compression ...

Page 240: ...210784GEG0029US0 Fuel Iniection Pressure 1 Set the injection nozzle to a nozzle tester 2 Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer in the nozzle holder to adjust it Fuel injection pressure Factory specification 13 73 to 14 70 MPa 140 0to 150 0kgf c...

Page 241: ...dead center of No 1 cylinder If injection timing is out of adjustment readjust the timing with shims Injection timing 3000min rpm D1005 E4B 0 3011 to 0 3272 rad 17 25 to 18 75 before T D C Injection timing 3200min rpm D1005 E4B 0 3360 to 0 3621 rad 19 25 to 20 75 before TD C Injection timing 3000min rpm D1105 E4B 0 3011 to 0 3272 rad 17 25 to 18 75 before TD C Injection timing 2600 min rpm Factory...

Page 242: ...ition or reduction of shim 0 025 mm 0 00098 in delays or advances the injection timing by approx 0 0044 rad 0 25 In disassembling and replacing the injection pump be sure to use the same number of new shims with the same thickness The 0 175 mm thick shim is coated only on the lower face Therefore do not use the 0 175 mm thick shim as the top shim of the combination injection pump side because this...

Page 243: ... that turn the flywheel by the hand and raise the pressure toapprox 13 73 MPa 140 0 kgf cm 1991 psi 7 Now tum the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 0to 130 0 kgf cm from 1991 to 1849 psi 8 Measure the time needed to decrease the pressure from 13 73 to 12 ...

Page 244: ...ble to the battery start with the positive terminal first Never check battery charge by placing a metal object across the posts 1 Disconnect the negative temiinal and positive terminal 2 Remove the battery holder 3 Remove the used battery 4 Replace the new battery 5 Tighten the battery holder 6 Connect the positive tenninal 7 Connect the negative terminal 9Y1210784GEG0035USO Replacing Radiator Hos...

Page 245: ...ns 3 Screw back the plug when bubbles do not come up any more 4 Open the air vent valve on top of the fuel injection pump 5 Ifequipped electrical fuel feed pump turn the key to AC position and pump the fuel up for 10 to 15 seconds If equipped mechanical fuel feed pump set the stop lever on stop position and crank the engine for 10 to 15 seconds 6 Close securely the air vent valve after air bleedin...

Page 246: ...the cleaner instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fillwith coolant up to FULL A mark on the recovery tank 3 8 Start and operate the engine for few minutes 9 Stop the engine and let cool Check coolant level of radiator and recovery tank 3 and add coolant if necessary IMPORTANT Do not st...

Page 247: ...06 223 50 37 35 108 226 At 1 01 100000 Pa 760 mmHg pressure atmospheric Use a radiator pressure cap that lets the pressure collect In the cooling system to get a higher boiling point NOTE The above data is the industrial standards that shows the minimum giycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep...

Page 248: ...ptor G 3 Adaptor A 9 Adaptor H 4 Adaptors 10 Adaptor I 5 Adaptor C 11 Adaptor J 6 Adaptor E 9Y1210784GEG0039US0 Diesel Engine Compression Tester for Glow Plug Hole Code No 07909 39081 Assembly 07909 31291 K 07909 31301 L 07909 31311 M Application Use to measure diesel engine compression and diagnosis of need for major overhaul Adaptor L for 05 series 1 Gauge 4 Adaptor K 2 Hose Assembly 5 Adaptor L...

Page 249: ...erial Steel E Hex nut 27 mm 1 1 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut 1 17 mm dia 0 67 in dia J 8 0 mm dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 241 to 0 244 In dia N 8 0 mm 0 31 in O 4 0 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 In dia Q PF1 2 R 23 mm 0 91 in S 17 mm 0 67 in T 4 0 mm ...

Page 250: ...liamfer 1 0 mm 0 039 in 02 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 30 mm 0 012 in 9Y1210784GEG0043OS0 Bushing Replacing Tool Application Use to press out and press fit the bushing 1 For small end bushing A 157 mm 6 18 in B 24 mm 0 94 in C 120 mm 4 72 in D 21 8 to 21 9 mm dia 0 859 to 0 862 in dia E 24 8 to 24 9 mm dia 0 977 to 0 980 in dia F 20 mm dia 0 79 in dia a 6 3 pm 250 pin b 6 3 pm 250 pin 0...

Page 251: ... 72 mm 2 8 in 0 40 mm radius 1 6 in radius D 10 mm 0 39 in E 24 mm 0 94 in F 20 mm dia 0 79 in dia G 51 20 to 51 40 mm dia 2 016 to 2 023 in dia H 47 30 to 47 50 mm dia 1 863 to 1 870 in dia 01 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in 00 3 Chamfer 0 30 mm 0 012 in Press F t A 135 mm 5 31 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D 10 mm 0 39 in E 24 mm 0 94 in F 20 mm dia 0 79 in di...

Page 252: ...t and to press fit the governor gear holder bushing A C1 Chamfer 1 0 mm 0 039 in B 73 90 to 74 00 mm dia 2 910 to 2 913 in dia C 69 80 to 69 90 mm dia 2 748 to 2 751 in dia D 30 mm dia 1 2 in dia E C2 Chamfer 2 0 mm 0 079 in F 18 mm 0 71 in G 150 mm 5 91 in H 188 mm 7 40 in 9Y1210784GEG0047US0 G 34 KiSC issued 04 2014 A ...

Page 253: ... dia 2 0 in dia L 40 mm dia 1 6 in dia M 10 mm 0 39 in N 33 mm 1 3 in 0 20 mm dia 0 79 in dia P 40 mm dia 1 6 in dia Q 72 10 to 72 15 mm dia 2 839 to 2 840 in dia R 73 mm dia 2 9 in dia S 83 mm dia 3 3 in dia 00 3 Chamfer 0 30 mm 0 012 in 01 Chamfer 1 0 mm 0 039 in 05 Chamfer 5 0 mm 0 20 in 2 Sleeve Guide A 42 mm 1 7 In B 12 mm 0 47 In 0 30 mm 1 2 In D mo X Pitch 1 25 E 2 0 mm 0 079 In F 10 mm 0 3...

Page 254: ...1 ENGINE n KiSC issued 04 2014 A ...

Page 255: ...MECHANISM CONTENTS 1 ENGINE BODY 1 CLOSED BREATHER 2 HALF FLOATING HEAD COVER D1305 E4B E4BG 3 GOVERNOR 4 BOOST COMPENSATOR KiSC issued 04 2014 A ...

Page 256: ...e manifold through breather valve 3 to be used for re combustion 1 BreatherTube 2 Cylinder Head Cover 3 Breather Valve 4 Oil Shield 5 Rubber Packing 9Y12i0784ENM0001US0 2 HALF FLOATING HEAD COVER D1305 E4B E4BG 3EEABAB1P004A The rubber packing is fitted in to maintain the cylinder head cover 0 5 mm 0 02 in or so off the cylinder head This arrangement helps reduce noise coming from the cylinder hea...

Page 257: ... 2 is hooked to a slide plate and holds the control rack in the direction of the full fuel position Fork lever 2 9 and the floating lever are installed in fork lever 1 6 with the fork lever shaft 4 The max torque limitation 1 device limits the amount of the fuel injection at the overload with the torque pin 1 Max Torque Limiter 2 Start Spring 3 Governor Spring 4 Fork Lever Shaft 5 Flyweight 6 Fork...

Page 258: ... fuel supply and suppresses the generation of black smoke 1 Max Torque Limiter 6 Fork Lever 1 7 Floating Lever 8 Torque Pin 9 Fork Lever 2 10 Fuel Limitation Bolt a Distance to which torque pin 8 pushes fork lever 1 6 out b Increase of fuel 9Y1210784ENM0005USO Two Lever Tvpe Fork Lever for BG tv The engine speed of BG engine 1800 min rpm specification The fork lever assembly of BG series is compos...

Page 259: ...um 9Y1210784ENM0007US0 mil 11 3EEAEAC1P012B V m o c c 3EEAEAC1P013A Boost compensator is the device that reduces black smoke during the engine startup and acceleration The rod of actuator 2 is pushed out by the rise of boost pressure and the plate 3 moves in the direction of the fuel increase around the fulcrum A 9Y1210784ENM0008US0 1 M4 KiSC issued 04 2014 A ...

Page 260: ... 1 S16 4 Fuel System 1 819 5 Electrical System 1 S23 2 DISASSEMBLING AND ASSEMBLING 1 S27 1 Draining Oil and Coolant 1 S27 2 External Components 1 S27 3 Cylinder Head and Valve 1 S28 4 Gear Case and Timing Gears 1 S32 5 Piston and Connecting Rod 1 S38 6 Flywheel and Crankshaft 1 S41 7 Alternator 1 S44 8 Starter 1 S45 3 SERVICING 1 S47 1 Cylinder Head and Valves 1 S47 2 Timing Gears Camshaft and Go...

Page 261: ...l camshaft worn Replace 1 S37 Injection nozzle clogged Clean or replace 1 S21 1 S23 Injection pump malfunctioning Repair or replace 1 S20 1 S36 Seizure of crankshaft camshaft piston cylinder or bearing Repair or replace 1 S37 1 S38 1 S39 1 S40 1 S58 1 S59 1 S60 1 S61 1 S62 1 S63 1 S64 Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S29 1...

Page 262: ...evel Piston ring and cylinder worn or stuck Repair or replace 1 839 1 840 1 864 Inconrect injection timing Adjust 1 819 Either Black or Dark Gray Exhaust Gas Is Observed Overload Lessen the load Low grade fuel used Use specified fuel 1 5 1 6 Fuel filter clogged Replace G 16 Air cleaner clogged Clean or replace G 12 G 15 G 20 Deficient nozzle injection Repair or replace nozzle 1 821 1 823 Deficient...

Page 263: ...n Repair or replace nozzle 1 821 1 823 Injection pump broken Replace 1 836 Water Mixed into Lubricant Oil Head gasket damaged Replace 1 830 1 831 Cylinder block or cylinder head flawed Replace 1 830 1 831 Low Oil Pressure Engine oil insufficient Replenish G 9 Oil strainer clogged Clean 1 838 Relief valve stuck with dirt Clean Relief valve spring weaken or broken Replace Excessive oil clearance of ...

Page 264: ...ow route corroded Clean or replace G 17 G 26 Radiator cap damaged Replace Overload running Reduce the load Head gasket damaged Replace 1 830 1 831 Incorrect injection timing Adjust 1 819 Unsuitable fuel used Use specified fuel 1 5 1 6 Battery Quickly Discharged Battery electrolyte insufficient Replenish distilled water and charge G 13 Fan belt slips Adjust belt tension or replace G 12 G 13 Wiring ...

Page 265: ...ylinder Head Surface Flatness 0 05 mm 0 002 in Valve Recessing Intake and Exhaust 0 050 to 0 25 mm 0 0020 to 0 0098 in 0 40 mm 0 016 in Valve Stem to Valve Guide Clearance 0 035 to 0 065 mm 0 0014 to 0 0025 in 0 10 mm 0 0039 in Valve Stem O D 6 960 to 6 975 mm 0 2741 to 0 2746 in Valve Guide I D 7 010 to 7 025 mm 0 2760 to 0 2765 in Valve Face Angle Intake 1 0 rad 60 Angle Exhaust 0 79 rad 45 Valv...

Page 266: ...00448 in 0 15 mm 0 0059 in Idle Gear 1 to Injection Pump Gear Backlash 0 0340 to 0 116 mm 0 00134 to 0 00456 in 0 15 mm 0 0059 in Idle Gear 1 to Idle Gear 2 Backlash 0 0330 to 0 117 mm 0 00130 to 0 00460 in 0 15 mm 0 0059 in Idle Gear 2 to Governor Gear Backlash 0 0300 to 0 117 mm 0 00119 to 0 00460 in 0 15 mm 0 0059 in Governor Gear Governor Gear to Injection Pump Gear Backlash 0 0300 to 0 117 mm...

Page 267: ...to 0 86665 in 22 03 mm 0 8673 in Piston Pin to Small End Bushing Clearance 0 014 to 0 038 mm 0 00056 to 0 0014 in 0 15 mm 0 0059 in Piston Pin O D 22 002 to 22 011 mm 0 86622 to 0 86657 In Small End Bushing I D 22 025 to 22 040 mm 0 86713 to 0 86771 In Piston Ring Gap D1005 E4B E4BG Top Ring 0 30 to 0 45 mm 0 012 to 0 017 in 1 25 mm 0 0492 in Second Ring 0 30 to 0 45 mm 0 012 to 0 017 in 1 25 mm 0...

Page 268: ...V1505 E4B E4BG Crankshaft Journal Oil Clearance O D 0 034 to 0 095 mm 0 0014 to 0 0037 in 47 934 to 47 950 mm 1 8872 to 1 8877 in 0 20 mm 0 0079 in Crankshaft Bearing 2 I D 47 984 to 48 029 mm 1 8892 to 1 8908 in Crankshaft to Crankshaft Bearing 2 D1305 E4B E4BG Oil Clearance 0 0340 to 0 103 mm 0 00134 to 0 00405 in 0 20 mm 0 0079 in Crankshaft Journal O D 51 921 to 51 940 mm 2 0442 to 2 0448 in C...

Page 269: ...294 to 441 kPa 3 00to 4 49 kgf cm 42 7 to 63 9 psi 147 kPa 1 50 kgf cm 21 3 psi Engine Oil Pressure D1005 E4BG D1105 E4BG D1305 E4BG V1505 E4BG At Idle Speed At Rated Speed 245 to 392 kPa 2 50 to 3 99 kgf cm2 35 6 to 56 8 psi 147 kPa 1 50 kgf cm2 21 3 psi Inner Rotor to Outer Rotor Clearance 0 060 to 0 18 mm 0 0024 to 0 0071 in Outer Rotor to Pump Body Clearance 0 100 to 0 180 mm 0 00394 to 0 0070...

Page 270: ... rad 13 25 to 14 75 before T D C D1005 E4BG D1105 E4BG Injection Timing 1800 min rpm 0 2575 to 0 2836 rad 14 75 to 16 25 before T D C D1305 E4BG V1505 E4BG Injection Timing 1800min rpm 0 2487 to 0 2748 rad 14 25 to 15 75 before T D C Pump Element Fuel Tightness 13 73 MPa 140 0kgf cm 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 0 130 1 kgf cm2 1991 1850 psi 5 seconds 13 731...

Page 271: ... 5 mm 0 413 in Starter Electromagnetic Drive Type Commutator O D 28 0 mm 1 10 in 27 0 mm 1 06 in Difference O D Less than 0 05 mm 0 002 in 0 4 mm 0 02 in Mica Undercut 0 50 to 0 80 mm 0 020 to 0 031 in 0 20 mm 0 0079 in Brush Length 16 0 mm 0 630 in 10 5 mm 0 413 in Alternator Stator Resistance Less than 1 0 Q Rotor Resistance 2 9 Q Slip Ring O D 14 4 mm 0 567 in 14 0 mm 0 551 in Brush Length 10 0...

Page 272: ...tening torque is not specified refer to the table below for the none specified torques values Indication on top of bolt No grade or 4T C7 7T Indication on top of nut O No grade or4T Unit N m l gf m Ibf ft Nm kgfm Ibfft M6 7 9 to 9 3 0 80 to 0 95 5 8 to 6 8 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 M8 18 to 20 1 8 to 2 1 13 to 16 24 to 27 2 4 to 2 8 18 to 20 M10 40 to 45 4 0 to 4 6 29 to 33 49 to 55 5...

Page 273: ...ker ann bracket nut D1005 E4B E4BG D1105 E4B E4BG V150S E4B E4BG M7X1 0 22 to 26 2 2 to 2 7 16 to 19 Rocker arm bracket screw D1305 E4B E4BG M7x 1 0 22 to 26 2 2 to 2 7 16 to 19 Idle gear shaft screw M6X1 0 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Fan drive pulley screw M14X1 5 236 to 245 24 0 to 25 0 174 to 180 Bearing case cover mounting screw M6X1 0 10 8 to 12 2 1 10 to 1 25 7 96 to 9 04 Glow plu...

Page 274: ...asurement is below the allowable limit apply a small amount of oilto the cylinder wall through the glow plug hole or nozzle hole and measure the compression pressure again ifthe compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head Ifthe compression pressure increases after applying oil check the cylinder wall and piston rings NOTE Ch...

Page 275: ...6 28 rad 360 and align the 1TC mark 1 on the flywheel and alignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge Adjustable Cylinder Location of Piston 3 cylinder 4 cylinder IN EX IN EX When No 1 piston is at compression top dead center 1 2 3 4 When No 1 piston is at overlap position 1 2 3 ...

Page 276: ...gf cm 7 1 psi At rated speed Factory specifica tion 197 to 441 kPa 2 00to 4 50 kgf cm2 28 5 to 64 0 psi Allowable limit 147 kPa 1 50kgf cm 21 3 psi When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque 15 to 19 Nm Tightening torque Oil pressure switch 1 5to2 0kgf m 11 to 14 Ibfft 9yi210 784ENS0008OS0 Fan Belt Tension 1 Measure the d...

Page 277: ... If the measurement is less than the factory specification replace the radiator cap 1 2 14 3TAAAAB1P060A 1 2 3EEABAB1P161B 2 3 More than 10 seconds for pressure fall Pressure falling time Factory specification 88 59 l Pa 0 89 0 61 kgf cm 12 8 6 psi 1 Radiator Tester 2 Adaptor 9Y1210784ENS0010US0 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester 1 a...

Page 278: ... when the valve opens and leaves the string 3 Continue heating and read the temperature when the valve opens approx 8 mm 0 3 in 4 If the measurement is not within the factory specifications replace the thermostat Thermostat s valve opening temperature Factory specification 69 5 to 72 5 C 157 1 to 162 5 F Temperature at which thermostat completely opens Factory specification 85 X 185 F 9Y1210784ENS...

Page 279: ... 1 cylinder If injection timing is out of adjustment readjust the timing with shims Injection timing 3000min rpm D1005 E4B 0 3011 to 0 3272 rad 17 25 to 18 75 before T D C Injection timing 3200min rpm D1005 E4B 0 3360 to 0 3621 rad 19 25 to 20 75 before TD C Injection timing 3000min rpm D1105 E4B 0 3011 to 0 3272 rad 17 25 to 18 75 before TD C Injection timing 2600 min rpm Factory specifica tion D...

Page 280: ...GEG0032US0 Fuel Tightness of Pump Element 1 Remove the engine stop solenoid 2 Remove the injection pipes and glow plugs 3 Install the injection pump pressure tester to the injection pump 4 Install the injection nozzle 2 jetted with the proper injection pressure to the injection pump pressure tester 1 Refer to the photo 5 Set the speed control lever to the maximum speed position 6 Run the starter t...

Page 281: ... the measurement is less than allowable limit replace the pump with new one or repair with a Kubota authorized pump service shop Fuel tightness of delivery valve Factory specification Allowable limit 10 seconds 13 73 12 75 MPa 140 0 130 1 kgf cm 1991 1850 psi 5 seconds 13 73 12 75 MPa 140 0 130 1 kgf cm 1991 1850 psi NOTE Never try to disassemble the injection pump assembly For repairs you are str...

Page 282: ...sure variation with 0 01 mm 0 0004 in difference of adjusting washer thickness Approx 235 kPa 2 4kgf cm 34 psi Fuel injection pressure Factory specification 1 Adjusting vy asher 13 73 to14 70 MPa 140 0to 150 0kgf cm2 1992 to 2133 psi 9Y1210784ENS0016US0 Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester 2 Raise the fuel pressure and keep at 12 75 MPa 130 kgf cm 1849 psi for 10 seco...

Page 283: ...ttach the positive cable to the positive terminal before the negative cable is attached to the negative terminal Never remove the battery cap while the engine is running Keep electrolyte away from eyes hands and clothes Ifyou are spattered with it wash it away completely with water immediately Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes ver...

Page 284: ...F electrolyte temperature 68 Measured value C Measured value T 0 0007 X 0 0004 X Specific Gravity State of Charge 1 260 Sp Gr 100 Ctiarged 1 230 Sp Gr 75 Charged 1 200 Sp Gr 50 Charged 1 170 Sp Gr 25 Charged 1 140 Sp Gr Very LittleUseful Capacity 1 110 Sp Gr Discharged At an electrolyte temperature of 20 C 68 F Motor Test 9Y1210784GEG0025US0 CAUTION Secure the starter to prevent it from jumping up...

Page 285: ... out the magnetic switch is failure Repair or replace the starter NOTE B terminal It is the terminal which connects the cable from the battery to the starter S terminal It is the terminal which connects the cable from the starter switch to the magnet switch 1 S Terminal 2 Positive Terminal 3 Negative Temiinal A Electromagnetic Drive Type B Planetary Gear Reduction Type 9Y1210784ENS0021US0 Magnet S...

Page 286: ...cifications disassemble the alternator and check the each component part for finding out the failure See the DISASSEMBLING AND ASSEMBLING and SERVICING for alternator Regulating voltage at no load Factory specification 13 8 to 14 8 Vat 25 C 77 F 9Y1210784ENS0023US0 Glow Plug Lead Terminal Voltage 1 Turn the key switch to the GLOW or PREHEAT position and measure the voltage with a circuit tester be...

Page 287: ...ttery 3 Switch for Holding Coil 4 Switch for Pulling Coil P Terminal for Pulling Coil H Terminal for Holding Coil 9Y1210784ENS0026US0 2 DISASSEMBLING AND ASSEMBLING 1 Draining Oil and Coolant Draining Oil and Coolant 2 External Components 3EEAEAC1P054A _ CAUTION Never remove radiator cap until coolant temperature is below its boiling point Then loosen cap slightly to the stop to relieve any excess...

Page 288: ...ft D1305 E4B E4BG3 Tlgtrtening torque Cylinder tiead cover screw 9 81 to 11 2 Nm 1 00 to 1 15kgfm 7 24 to 8 31 Ibf ft 1 Breather Hose 2 Cylinder Head Cover Screw 3 Cylinder Head Cover Injection Pipes A D1005 E4B E4B6 D1105 E4B E4B6 V1S05 E4B E4BG B D130S E4B E4BG 9Y1210784ENS0030USO 1 Loosen the screws to the pipe clamp 1 2 Detach the injection pipes 2 When reassembling Send compressed air into th...

Page 289: ...7 9 to 14 N m 0 80 to 1 5 kgf m 5 8 to 10 Ibffl 1 Overflow Pipe 2 Lead 3 Glow Plug 4 Nozzle Holder Assembly 5 Copper Gasket 6 Heat Seal 9Y1210784ENS0032US0 Nozzle Heat Seal Service Removal Procedure IMPORTANT Use a plus philllps head screw driver 1 that has a diameter which is bigger than the heat seal hole Approx 6 mm 1 4 in 1 Drive screw driver 1 lightly into the heat seal hole 2 Turn screw driv...

Page 290: ...s are properly engaged with the dimples IMPORTANT After Installing the rocker arm be sure to adjust the valve clearance D1005 E4B E4BG D110S E4B E4BG VH505 E4B E4BG Tightening torque Rocl er arm bracket nut 22 to 26 Nm 2 2to2 7kgfm 16to19lbfft D1305 E4B E4BG Tightening torque Rocker arm bracket screw 22 to 26 Nm 2 2 to 2 7 kgfm 16to19Ibftt 1 Rocker Ann Assembly 2 Push Rod 3 Tappet 1 S30 A D1005 E4...

Page 291: ... After applying engine oil to the thread of screws tighten them in several steps and specified sequence a to n or r NOTE Do not use 0 ring on the pin pipe It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up 64 to 68 N m Tightening torque Cylinder head screw 6 5 to 7 0 kgf m 47 to 50 ibfft 1 Clamp 2 Return Pipe 3 Pin Pipe A 3 Cylinder B 4 ...

Page 292: ...hemnostat cover side of the gasket 3 1 Thermostat Cover Mounting Screw 3 Thermostat Cover Gasket 2 Thermostat Cover 4 Themiostat Assembly 9Y1210784ENS0038US0 5 Valve Spring 6 Valve Stem Seal 7 Valve Gear Case and Timing Gears 3EEAEAE1P008A iffi iffl iffi 3TAAAAB1P057A Oil Pan and Oil Strainer for Extended Oil Pan 1 Remove the oil pan mounting screws 2 Remove the oil pan 2 3 Remove the oil strainer...

Page 293: ...the fan drive pulley with a puller When reassembling Install the pulley to crankshaft aligning the mark 1 on them 3 cylinder engine Apply engine oil to the fan drive pulley retaining screw And tighten it 236 to 245 Nm Tightening torque Fan drive pulley saew 24 0 to 25 0 kgfm 174 to 180 ibf tt 1 Aligning Mark 9Y1210784ENS0040US0 1 S33 KiSC issued 04 2014 A ...

Page 294: ... off 1 Gear Case a Bolt Length 45 mm 1 8 in b Bolt Length 50 mm 2 0 In A Gear Case for Standard Oil Pan c Bolt Length 55 mm 2 2 In B Gear Case for Extended Oil Pan d Bolt Length 65 mm 2 6 in C Gear Case for BG Type e Bolt Length 68 mm 2 7 in Except D130S E4BG f Bolt Length 70 mm 2 8 in g Bolt Length 85 mm 3 3 in h Nut j Bolt Length 59 mm 2 3 in k Bolt Length 82 mm 3 2 in 9yi210784ENS0041tJS0 1 S34...

Page 295: ...boost compensator assembly 2 When reassembling 1 Install the stop solenoid mounting bolt 3 in boost compensator assembly 2 and assemble it to the boost compensator installation position at the same time 2 Tighten the boost compensator mounting bolt 5 3 Remove the stop solenoid mounting bolt 3 4 Install the stop solenoid 1 and tighten the mounting bolt 3 NOTE Apply a liquid gasket Three Bond 1217D ...

Page 296: ...ssembled When reassembling When installing the injection pump insert the control rack pin 2 firmly into the groove 7 of the thrust lever of fork lever NOTE Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing be sure to use the same number or new gasket shims with the same thickness 1 Notch 2 Control Rack Pi...

Page 297: ...tion Make sure to assemble the external snap ring of the governor shaft Check the govemor shaft for smooth rotation IMPORTANT There is a model of idle gear 1 4 and idle gear 2 7 by the difference of the method of transmission the power to the governor gear 6 When replacing the ball bearing of governor shaft securely fit the ball bearing 10 to the crankcase apply an adhesive Three Bond 1324B or equ...

Page 298: ...an using waste cloth soaked with gasoline Apply liquid gasket Three Bond 1207D or equivalent about 3 0 to 5 0 mm 0 12 to 0 19 in thick Within 20 minutes after the application of liquid gasket reassemble the components 1 O ring 2 Screw 3 Oil Strainer Connecting Rod 4 Oil Pan 5 Oil Pan Mounting Screw 9Y1210 784ENS0045US0 1 Remove the connecting rod cap When reassembling Align the marks a with each o...

Page 299: ...der face the mark on the connecting rod to the injection pump IMPORTANT Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into the cylinder place the gaps of all the piston rings as shown in the figure Carefully insert the pistons using a piston ring compressor 1 Otherwise their ...

Page 300: ...the opposite side of the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 NOTE Mark the same number on the connecting rod and the pisto...

Page 301: ...emove the bearing case cover mounting screws 2 Remove the bearing case cover 6 IMPORTANT The length of inside screws 1 and outside screws 2 are different Do not teke a mistake using inside screws and outside screws When reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 6 to position the casting mark UP on it upward...

Page 302: ... third cylinder to the A Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder 3 Turn the crankshaft by 2 09 rad 120 counterclockwise to set the crankpin of the second cylinder to the A Draw out the crankshaft until the crankpin of the first cylinder comes to the center of third cylinder 4 Repeat the above steps to draw out all the cranksh...

Page 303: ... makings b A B C from the gear case side Match the alignment numbers a on the main bearing case assembly 1 When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 3 with its oil groove facing outward Confirm that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque Tightening torque Main ...

Page 304: ...tor 10 5 Remove the four screws holding the stator lead wires 6 Remove the rectifier 9 7 Remove the rear end frame 8 8 Press out the rotor 6 from drive end frame 2 9 Remove the retainer plate 5 10 Press out the bearing 4 from drive end frame 2 with a press and jig 11 Lightly secure the rotor with a vise to prevent damage and remove the bearing 7 with a puller When reassembling Tightening torque Pu...

Page 305: ...move the solenoid switch 5 3 Remove the end frame cap 17 4 Remove the brake shoe 16 brake spring 15 and gasket 14 5 Unscrew the through bolts 22 and remove the rear end frame 13 6 Remove the brush from the brush holder while holding the spring up 7 Remove the brush holder 21 8 Draw out the yoke 19 from the starter drive housing 2 9 Draw out the armature 10 with the drive lever 3 NOTE Do not damage...

Page 306: ...frame 8 5 Remove the brush from the brush holder while holding the spring up 6 Remove the brush holder 9 7 Draw out the armature 5 from the yoke 4 8 Remove the housing 13 9 Remove the idle gear 7 and the overrunning clutch 6 10 Remove the magnet switch cover 10 11 Remove the plunger 11 NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO No 50 or equivalent to the id...

Page 307: ...ck the oil clearance of the crank pin journals and piston pins NOTE Top clearance Width of the crushed plastigauge 2 D1005 E4B E4BG Top clearance Factory specifica tion D1105 E4B E4BG V1505 E4B E4BG 0 55 to 0 75 mm 0 022 to 0 029 in D1305 E4B 0 80 to 1 0 mm E4BG 0 032 to 0 039 in 64 to 68 Nm Tightening torque Cylinder head screw 6 5 to 7 0 kgfm 47 to 50 Ibfft 1 Plastigauge 2 Caished Plastigauge 3 ...

Page 308: ...e valve 5 If it still exceeds the allowable limit after replacing the valve replace the cylinder head Valve recessing Factory specification 0 050 protrusion to 0 25 recessing mm 0 0020 protrusion to 0 0098 recessing in Allowable limit 0 40 recessing mm 0 016 recessing in 1 Cylinder Head Surface A Recessing B Protrusion 9Y121O784ENSOO60US0 Clearance between Valve Stem and Valve Guide 1 Remove carbo...

Page 309: ...tion 7 010 to 7 025 mm 0 2760 to 0 2765 in I NOTE Do not hit the valve guide with a hammer during replacement A When Removing B When Installing 9Y1210784ENS0062US0 Valve Seating Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact If the valve does not seat all the way around the valve seat or the valve contact is less than 70 correct the valve seating ...

Page 310: ...ating apply a thin film of compound between the valve face and valve seat and fit them with valve lapping tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around Valve seat angle Factofy specifica tion IN 1 0 rad 60 EX 0 79 rad 45 1 Valve Seat Width 2 Identical Dimensions Valve Lapping 1 2 A Check Contact B Correct Seat Width C Check ...

Page 311: ...s actually compressed in the engine 2 Read the compression load on the gauge 3 Ifthe measurement is less than the allowable limit replace it Setting load Setting length Factory specification Allowable limit 117 4 N 31 0 mm 11 97 kgf 31 0 mm 26 39 lbf 1 22 in 100 0N 31 0 mm 10 20 kgf 31 0 mm 22 48 lbf 1 22 in 9Y121078 4ENS0067USO Oil Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the r...

Page 312: ... with an outside micrometer 2 Measure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet Oil Clearance between tappet and tappet guide bore Factory specification 0 020 to 0 062 mm 0 00079 to 0 0024 in Allowable limit 0 07 mm 0 003 in Tappet O D Factory specification 19...

Page 313: ...00456 in Allowable limit 0 15 mm 0 0059 in equipped with idle gear 2 Backlash between idle gear 1 and idle gear 2 Factory specification 0 0330 to 0 117 mm 0 00130 to 0 00460 in Allowable limit 0 15 mm 0 0059 in 9Y1210784ENS0071OS0 Governor Gear Backlash Backlash between injection pump gear and governor gear Factory specification 0 0300 to 0 117 mm 0 00119 to 0 00460 in Allowable limit 0 15 mm 0 00...

Page 314: ...V blocks on the surface plate at both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft Camshaft alignment Allowable limit 0 01 mm 0 0004 in 9Y1210784ENS0075OS0 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 Ifthe measuremen...

Page 315: ...2 Measure the idle gear bushing I D with an inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the bushing Ifit stillexceeds the allowable limit replace the idle gear shaft Oil clearance between idle gear shaft 1 and 2 and idle gear bushing Factory specification 0 020 to 0 054 mm 0 00079 to 0 0021 in Allowable limit 0 10 mm 0 0039 in Idle g...

Page 316: ... and small end bushing Factory specification 0 014 to 0 038 mm 0 00055 to 0 0014 in Allowable limit 0 15 mm 0 0059 in Piston pin O D Factory specification 22 002 to 22 011 mm 0 86622 to 0 86657 in Small end bushing I D Factory specification 22 025 to 22 040 mm 0 86713 to 0 86771 in 9Y1210784ENS0081US0 Replacing Small End Bushing When removing 1 Press out the used bushing using a small end bushing ...

Page 317: ...er part of the cylinder the least worn out part with a piston 2 Measure the ring gap with a thickness gauge 3 If the measurement exceeds the allowable limit replace the piston ring Top ring Factory specifica tion 0 30 to 0 45 mm 0 012 to 0 017 in Allowable limit 1 25 mm 0 0492 in Piston ring gap D100S E4B E4B6 Second ring Factory specifica tion 0 30 to 0 45 mm 0 012 to 0 017 in Allowable limit 1 2...

Page 318: ...e limit 0 2 mm 0 008 in Oil ring Factory specifica tion 0 02 to 0 06 mm 0 0008 to 0 002 in Allowable limit 0 15 mm 0 0059 in 9Y1210784BNS0085US0 Cranl shaft Side Clearance 1 Set a dial indicator with its point on the end of the crankshaft 2 Move the crankshaft to the front and rear to measure the side clearance 3 Ifthe measurement is more than the allowable limit replace the thrust bearings 4 if t...

Page 319: ...rankpin wear replace it with an undersize one referring to the table and figure NOTE Never insert the plastigage into the crankpin oil hole Be sure not to move the crankshaft while the connecting rod screws are tightened Oil clearance between crankpin and crankpin bearing Factory specification Allowable limit 0 029 to 0 091 mm 0 0011 to 0 0036 in 0 20 mm 0 0079 In Crank pin O D Factory specificati...

Page 320: ... Dimension B 1 0 to 1 5 mm relief 0 040 to 0 059 in relief 1 0 to 1 5 mm relief 0 040 to 0 059 in relief Dimension C 47 734 to 47 750 mm dia 1 8793 to 1 8799 in dia 47 534 to 47 550 mm dia 1 8715 to 1 8720 in dia The crankshaft joumal must be fine finished to higher than Rmax 0 8S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 to 0 059 in relief D1305 E4B E4BG Oil clearance betwe...

Page 321: ...talling 1 Clean a new crankshaft bearing 1 and crankshaft journal bore and apply engine oil to them Using a crankshaft bearing 1 replacing tool press fit a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure 2 Dimension A 1 Seam 2 Crankshaft Bearing 1 3 Cylinder Block 1 S61 Factory specification 0 to 0 3 mm 0 to 0 01 in A Dimension 9Y121O784ENS0O9OUSO KiSC issued...

Page 322: ...ion 47 934 to 47 950 mm 1 8872 to 1 8877 in Crankshaft bearing 2 I D Factory specification 47 984 to 48 029 mm 1 8892 to 1 8909 in Oil clearance between crankshaft journal and crankshaft bearing 3 Factory specification 0 0340 to 0 103 mm 0 00134 to 0 00405 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory specification 51 921 to 51 940 mm 2 0442 to 2 0448 in Cranksh...

Page 323: ... 0079 in 0 40 mm 0 016 in Dimension A 2 3 to 2 7 mm radius 0 091 to 0 10 in radius 2 3 to 2 7 mm radius 0 091 to 0 10 in radius Dimension 8 1 0 to 1 5 mm relief 0 040 to 0 059 in relief 1 0 to 1 5 mm relief 0 040 to 0 059 in relief Dimension 0 51 721 to 51 740 mm dia 2 0363 to 2 0370 in dia 51 521 to 51 540 mm dia 2 0284 to 2 0291 in dia The crank pin must be fine finished to higher than Rmax 0 8S...

Page 324: ... Allowable D1105 E4B E4BG ilmit D1305 E4B E4BG V1505 E4B E4BG 78 15 mm 3 077 in A Top a 8 iVIiddie b 0 Bottom SItirt 9Y1210784ENS0093US0 Correcting Cylinder 1 When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension Right angled to Piston Pin Piston Pin Direction Oversized cylinder liner I D Factory specifica tion D1005 E4B E4BG 76 500 to 76 519 mm 3 0119 to...

Page 325: ...0784ENS0096OS0 Clearance between Rotor and Cover 1 Put a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 Ifthe clearance exceeds the factory specifications replace the oil pump rotor assembly Clearance between rotor and cover Factory specificat...

Page 326: ...r O D Gear reduction type 30 0 mm 1 18 in Allowable Electromagnetic drive type 27 0 mm 1 06 in limit Gear reduction type 29 0 mm 1 14 in Factory specifica tion Electromagnetic drive type Less than 0 05 mm 0 002 in Difference of O D s Gear reduction type Less than 0 02 mm 0 0008 in Allowable Electromagnetic drive type 0 4 mm 0 02 in limit Gear reduction type 0 05 mm 0 002 in Mica under cut Factory ...

Page 327: ...istance range of circuit tester 2 If it conducts replace the armature 3 Check the continuity across the segments of the commutator with resistance range of circuit tester 4 If it dose not conduct replace the armature 9Y1210784ENS0102OS0 Field Coll 1 Check the continuity across the lead 1 and brush 2 with a circuit tester 2 If it dose not conduct replace the yoke assembly 3 Check the continuity acr...

Page 328: ...e is not the factory specification replace it 3 Check the continuity across the slip ring and core with resistance range of circuit tester 4 If infinity is not indicated replace it Resistance Factory specification 2 9 Q 9Y1210784ENS0106US0 Slip Ring 1 Check the slip ring for score 2 Ifscored correct with an emery paper or on a lathe 3 Measure the O D of slip ring with vernier calipers 4 Ifthe meas...

Page 329: ... in the rectifier conducts in one direction and does not conduct in the reverse direction 9Y1210784ENS0109OS0 IC Regulator 1 Check the continuity across the B tenninal 2 and the F terminal 1 of IC regulator with resistance range of circuit tester 2 The IC regulator is normal if the conducts in one direction and does not conduct in the reverse direction 1 F Terminal 2 8 Terminal 9Y1210784ENS0110OS0...

Page 330: ...ice Department Address 64 Ishizu Kitamachi Sakai Ku Sakai City Osaka 590 0823 Japan Phone 81 72 241 1129 Fax 81 72 245 2484 E mail ksjg ksos pub kubota com Printed in Japan 2014 04 S El El engusa Code No 9Y111 07841 KUBOTA Corporation 2013 02 S El El engusa ...

Page 331: ...c A R 6 ...

Page 332: ... LF DUTRIGGFR LR OUTRIGGER R HPC IliijM PFJ MX I V wr k L V LEFT DRIVE RIGH T P MEAT EXCiiANGER FILTER H Y T R T A A U N L K C ENGINE HYDRAULIC SCHEMATIC B Hydraulic SCHCMATIC K 0 ...

Page 333: ...c H A R ...

Page 334: ...ine 3 Toggle any function switch to activate Yellow active light will flash fast 4 Twistthe E Stop button clockwise The button will pop out Yellow active light will flash slowly TO OPERATE THE MACHINE 1 Toggle a desired function 2 Pull trigger slowly to start function operation 3 Function operation will increase proportionally with trigger movement ...

Page 335: ...Installation I Configuration Manual T150 Transmitter R160 Receiver November 3 2011 Revision 4 DM R160 0664A 74 1833 Coast Meridian Road Port Coquitlam BC Canada V3C 6G5 Ph 604 944 9247 Fax 604 944 9267 Tdl Free 1 800 663 8806 ...

Page 336: ...This page is left intentionally blank DM Ri60 0864A Rev 03 www oiTinexcontrols com call toll free 1 800 663 8806 2 D ...

Page 337: ...OVIDE ASAFETY CUTOFF SWITCH Ifmaintenance is required the radio must be disconnected from power USE PROPER WIRING Loose or frayed wires can cause system failure intermittent operation machine damage etc DO NOT INSTALLIN HOT AREAS This apparatus can be damaged by heat in excess of 158 F 70 C Personal Safety MAKE SURE MACHINERY AND SURROUNDING AREA IS CLEAR BEFORE OPERATING Do not activate the re mo...

Page 338: ...sed radios The R160 receiver is designed to be powered from a 12 DC or 24VDC system Itfeatures 19 solid state high side driver input output controls and a reliable E Stop control The T150 transmitter comes with 4 to 6 switches and an optional proportional trigger control It uses standard long lasting AA batteries Each T150 transmitter uses a unique ID code to ensure that no two systems will confli...

Page 339: ...Output Engine Kill Output Input Output Input Output Input Output Trigger Output Proportional Current Input Output Input Output Input Output Input Output Input Output Input Output Input Output Hi Speed On Enable Output on with any track outputs Right Track Reverse Right Track Fonward Left Track Reverse Left Track Forward Switches to Power with Link Power Input 9Vto 30VDC Ground Outputs 19 solid sta...

Page 340: ...a good practice to make both the Power and Ground connections directly to the Battery and avoid connecting the power from the charging side of existing wiring or making use of existing ACC or other peripheral connection points Make sure that wire of sufficient gauge and insulator type is used when connecting the outputs of the receiver to the con trol panel Observe any component manufacturer s ins...

Page 341: ...e or mix with other battery types May explode or leak causing in jury Replace all batteries at the same time as a fresh set and do not mix and match battery types 1 Press E Stop 2 Press any switch O Ifthe transmitter s Active light does not flash check the battery orientation Toturn off the transmitter press the E Stop button Test the Transmitter I Receiver Link 3 Twist Clockwise Release E Stop Fo...

Page 342: ... Power T150 into Configuration Mode A B C mm HmTTTKi n J ESTOP FAULT IK STATUS 0 0 0 0 C ESTOP FAULT tK STATUS A o A A D A Hold SW 5 switch UP B Press E Stop C Twist clockwise release E Stop D Release SW 5 Switch 0 0 U to to m 11 4 Put R160 into Setup Mode A Press hold Setup button until Status light goes from slow flash to fast flash B Release Setup button Status light goes to solid GREEN Link li...

Page 343: ... to the receiver 2 Power T150 into Configuration Mode A B C C ESTOP FAULT tK STATUS A o A A D A Hold SW 5 switch DOWN B Press E Stop C Twist clockwise release E Stop D Release SW 5 Switch 0 O Ho JI0 to 3 Setup T150 A Press SW 5 switch DOWN 4 Set Minimum Level A Keep Trigger released to set mini mum level B Press SW 5 switch UP to increase minimum level or DOWN to decrease it 5 Set Maximum Level A ...

Page 344: ...ower up the transmitter or the unit will power down Normal Operation The transmitter is in Download Mode On Power Up Press and release the E Stop button within 10 seconds to power up the transmitter or the unit will power down Stuck switch detected Ensure that all switches are in a centered position The transmitter will not power up when a function is ON On Power Down Unit is still powered Check f...

Page 345: ...cted with one of the other outputs Transmitter is OFF A wiring short to the battery has been detected Transmitter is OFF The receiver has detected an internal fault Transmitter is OFF Blown fuse detected Transmitter is ON A setup failure has occunred Transmitter is OFF The receiver is powered incorrectly Light Legend ISolid ILTh Fast Flash Solution RefertoTroubleShootingChart 3forsolutions Todetec...

Page 346: ...64A Rev 03 Problem state E Stop Flashing RED Fault Light is OFF Fault Light is Flashing RED Fault Light is RED Inspect E Stop wiring looking for short circuits e g bare wires Disconnect the E Stop output as close to the receiver output as possible Ifthe Status light changes to GREEN there Is a short is the wiring after the discon nection point Stays flashing RED call for service Call for service T...

Page 347: ...ientation 2 Clean battery contacts 3 C heck or Replace batteries 4 Call for service Stuck switch 1 Return all switches to neutral OFF position 2 Toggle the switch a few times 3 Call for service Low Battery Change Batteries Note Low batteries will last approxi mately 10 hours once the Low Battery light begins to flash Replace batteries by next shift The transmitter is in Calibration mode 1 Turn uni...

Page 348: ... instead of the radio system Call for service Turn on the transmitter to check if the units function correctly If not proceed to Chart 1 Note Before you proceed with the Download ID procedure located on Page 8 great care and caution must be adhered to Also refer to Chart 4 for Tips and Considerations If by accident the transmitters have been switched with another unit by downloading the ID code to...

Page 349: ...fthis doesn t correct the problem send both the transmitter and receiver in for service Note you could try to determine whether the fault lies with the transmitter or receiver by completing the downloading procedure with a different transmitter Ifthis step works then the fault lies with the original transmitter If not the fault may lie with the receiver liCaution Note Before attempting downloading...

Page 350: ...247 Canada ISC RSS 2210 Europe EN 440 Australia C TIck FCC Rules and Compliance Wairanty This device complies vsith F rt 15 of he FCC Riles Qieration 8 subject b the following two condi tions t dvice ray ot cause brmful riterference ad 2 his obvice nust zcept aiy interference eceived ncluding interference that may cause unde sired operation FCC art 15 247 ISC SS2 B OMNEX ODntrol Systems he warrant...

Page 351: ...c H A R 8 ...

Page 352: ...e with 2 x 6 pressure treated wood deck Tongue Length 6 40 long with 6 degree slope 2 Two 12K oil bath slipper spring axles with electric brakes 67 5 spring centers and 89 5 hub face 4 215 75R 17 5 3 8 grade 70 36 overall length Rubber mounted sealed LED Sealed wire harness Brake Battery Breakaway switch LED battery box Pintle Eye 21 ton 3 pintle ring with vertical adjustment of 18 to 32 12K drop ...

Page 353: ...ice calls towing charges expediting freight ortransportation costsarethesoleresponsibility oftheconsumer andwill not be paid byNovae Corp Items Not Covered InThis Warranty 1 Wheels andTires Contact the lire manufacturer forwanranty information 2 Running Gear including axle and suspension assemblies Present all claims directly tothe axle manufacturer or their authorized dealers 3 Paint finish anddu...

Page 354: ... also Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve ftiel economy Increase the life of your tires The following information presents a comprehensive overview oftire safety including information on the following topics Basic tire maintenance Uniform Tire Quality Grading System Fundamental characteristics oftires Tire safety tips Use this inform...

Page 355: ...fthe vehicle The tire inflation pressure isa number that indicates the amount ofair pressure measured inpounds per square inch psi a tire requires to be properly inflated Youwill alsofindthis number on the vehicle information placard expressed inkilopascals kPa which isthe metric measure used internationally Manufacturers ofpassenger vehicles and light trucks determine this number based onthe vehi...

Page 356: ...information placard or certification label Step2 Recordthe tire pressureofall tires Step 3 Ifthetirepressure istoo high inanyofthetires slowly release airby gently pressing onthetirevalve stemwith the edge of your tiregauge until you get to the correct pressure Step 4 Ifthetirepressure istoolow note thedifference between themeasured tirepressure andthecorrect tirepressure These missing pounds ofpr...

Page 357: ...ng tread depth istoplace apenny inthetread with Lincoln s head upside down and facing you Ifyou can see the top ofLincoln s head you are ready for new tires Tire Balance and Wheel Alignment To avoid vibration orshaking ofthe vehicle when atire rotates the tire must be properly balanced This balance is achieved bypositioning weights onthewheel to counterbalance heavy spots on the wheel and tire ass...

Page 358: ... as personal driving style type ofcar quality ofthe roads and tiremaintenance habits have a significant influence on your tire s performance andlongevity Tread weargrades areanindication of a tire srelative wearrate Thehigher thetread wear number is thelonger it should takeforthetread to wear down Forexample a tire grade of400 should wear twice aslongasa tiregrade of200 Traction grades areanindica...

Page 359: ...ll for improved steering response and betteroverall handling on drypavement The R stands for radial Radial ply construction oftires has been the industry standard for the past 20 years Next number This two digit number is the wheel orrim diameter in inches Ifyou change your wheel size you will haveto purchasenew tires to match the new wheel diameter Next number This two or three digitnumber is the...

Page 360: ...d pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under nontial driving conditions UTQGS Information Tread wear Number This number indicates the tire s wear rate The higher the tread wear number is the longer it should take for the tread to wear down For example a tire graded 400 sh...

Page 361: ...theloaded trailer is transferred to thetowingvehicle Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash orcould cause injury ordeath you should immediately infomi theNational Highway Traffic Safety Administration NHTSA in addition to notifyingNovae Corporation at 1 800 372 1755 If NHTSA receives similar complaints It may open aninvestigation and ifIt fi...

Page 362: ... VIN Owners Name Street City State Zip Primary Use Store and Location where purchased Store Representative Name Address City State Zip Phone Number Delivery Date Signature FoW toconceal information tapeclosed affix postage and mail Novae Corp One Novae Parkway Markle IN 46770 PLACE POSTAGE HERE ...

Page 363: ...m ...

Page 364: ...pert Electric Brakes Properly 11 General Maintenance Electric Brakes 11 Brake Adjustment 11 Lubricate Brakes 12 Clean and Inspect Brakes 12 Magnets i Shoes and Linings 13 Axle and Suspension Installation 13 Suspension Systems 13 Double Eye LeafSprings 14 Slipper LeafSprings 14 Inspection 15 Suspension Replacement 16 Adjustable Spring Seats 16 Wheels 16 Wheel Selection 16 Torque Requirements 17 Tir...

Page 365: ... Lippert Components Inc thanks you for purchasing our Axles and Running Gear When you speak of Lippert Components Inc our quality stands beside you Safety Information AWARNIN The WARNING symbol above isa sign that a service or maintenance procedure has a safety riskinvolved and may cause death or serious injury ifnot performed safely and within the parameters set forth in this manual Always wear e...

Page 366: ...l will be fully cured from the heat and develop close to 100 contact with the brake drum surface This break in period not only seats the shoe lining material but also seats in the brake electromagnets During the break in period the linings will wear at a faster rate than they do after they are seated in NOTE Brakes should be manually adjusted after the first 200 miles of operation and periodically...

Page 367: ...ected NOTE Bearings MUSTalways be replaced in sets of one cone and one cup Always wear eye protection when servicing the axle brakes hubs springs and wheels Failure to wear eye protection may result in serious injury Follow the procedure below to replace the bearing cup 1 Place hub on a flat surface with bearing cup on the bottom 2 With brass drift punch lightly tap around the small end of the cup...

Page 368: ...ig 2 3 Repeat this process while turning bearing from roller to roller until all rollers are coated 4 Apply a light coat of grease into the bearing cup surface 5 Reassemble bearing into cup Rev 08 25 2015 Recommended Wheel Bearing Grease Specifications Thickener Type Dropping Point Consistency Additives Base Oil Base Oil Viscosity Viscosity Index Pour Point Mobil Oil Exxon Standard Kendal Refining...

Page 369: ... side marked AIR SIDE is away from bearing cone Bearinq AdiustnriGnt Hub Reolacement To adjust bearings or replace removed hub follow procedures below 1 Place hub bearing washers and castle nut back on axle spindle in the reverse order from which they were removed Castle nut should be torqued to 50 ft lb Hub will rotate during this process 2 Loosen castle nut to back off the torque 3 Tighten castl...

Page 370: ...g can damage the sealing o ring and cause an oil leak In order to remove hub rotor assembly a gear puller may be required The oil seal is a 2 part seal where the insidediameter of the seal presses onto the spindle journal and the outside diameter of the seal presses Into the hub bore Therefore a gear puller isthe most efficient way to remove hub from spindle A new oil seal MUSTbe installed before ...

Page 371: ...ot in nut does not align with hole in spindle back nut off until it does never tighten past finger tight 6 Bend legs over end of spindle and be sure legs do not interfere with oil cap upon reassembly Disc Brake Option Disc Brake Pads Disc brake pads are available through auto part stores Brake pads are a consumable item so be sure to visually check pads every 3 000 miles Besure to also check rotor...

Page 372: ...es are applied 2 From the tow vehicle s battery the electricity flows to the brake s electromagnet 3 When energized the magnets are attracted to the rotating surface of the drums 4 This moves the actuating levers in the direction the drums are turning 5 The actuating cam at the end of the shoe forces the primary shoe out to the drum surface 6 The force of the primary shoe actuates the secondary sh...

Page 373: ...i Rev 08 25 2015 Prior to testing or adjusting brakes be sure area is clear ofany persons and vehicles Failure to perform test in a clear area may result in death or serious injury Lippert Components Inc ElectricBrakesare automatic adjust only Ifmanual adjusting is needed the following 6 step procedure can be utilized The brakes should be adjusted inthe following manner 1 Jack up trailer and secur...

Page 374: ...or fatal illnesses Certain precautions MUSTbe taken when servicing brakes 1 Avoid creating and or breathing any brake dust 2 Do not machine file or grind the brake linings 3 Remove with a damp brush or cloth Dry brushing or compressed air willcause the dust particles to become airborne Magnets This electric braking system utilizes an electromagnet to actuate the brake shoes These high quality magn...

Page 375: ...e s Parallel installation allows for correct and safe control prolonged tread life and will all but eliminate dog tracking Proper alignment is most readily achieved by measuring from the center of the trailer king pin tothecenter of each end of the axles Lippert Components Inc tubular axles are made of high strength steel to prevent metal fatigue and provide the best possible welding conditions Th...

Page 376: ... 000 lb axles Tandem and triple axle mounting kits are available for both 33 and 35 axle spacing Slipper springs have a loop eye formed on one end and a reverse radius on the other The front eye is secured to either the front hanger or rear of the equalizer with a bolt and nut The slipper end rides against a wear block located in either the front of the equalizer or the rear hanger A keeper bolt o...

Page 377: ...the spring eye bolts and the spring 5 Ifthe spring eye bushings are to be replaced press out the old bushing by hand or tapping out with a punch 6 Free floating nylon bushing needs no lubrication Press the new bushing into the spring eye by hand or gently tapping it in with a bounceless rubber or plastic mallet 7 Reinstall repaired or replaced components in reverse order NOTE For multiple axle uni...

Page 378: ... Bolt Circle Wheels have many bolt circle variations and some are so close that it could be possible to attach an Inappropriate wheel that does not match the axle hub 2 Capacity Wheel load capacity should match tire and trailer max load ratings 3 Offset The relationship of the center line of the tire to the hub face of the axle should match any replacement Failure to match offset may result in red...

Page 379: ...t Chart below 3 Tightening fasteners should be done in stages Follow the recommended sequence Fig 8 tighten fasteners per wheel torque requirements chart below 4 Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and re torque after the 10 and 25 miles and again at 50 miles A periodic check during regular service is recommended Wheel Torque Requirement Char...

Page 380: ...use to insure maximum tire and tread life The following tire wear diagnostic chart will help you pinpoint the causes and solutions of tire wear problems NOTE Tire wear should be checked frequently because once a wear pattern becomes firmly established in a tire it is difficult to stop even ifthe underlying cause is corrected Problem Center Wear Edge Wear Side Wear Toe Wear Cupping Flat Spots Rev 0...

Page 381: ...ted Warranty or call our Service Department for any other related issues Measuring Voltage The BrakingSystem voltage is measured at the two lead wires of the magnet on any brake Use the pin probes inserted through the insulation of the lead wires Toensure that the battery isindicating a full charge the towing vehicle engine should be running with the trailer coupler connected when checking the vol...

Page 382: ...racked brake drums Over adjustment Out of round brake drums Incorrect brake components Loose bent or broken brake components Faulty breakaway switch Loose wheel bearing adjustment Bent spindle Find and correct Test and correct Adjust brakes Clean or replace Clean and correct cause of corrosion Replace Machine or replace Correct Adjust brakes Re burnish or replace Adjust Correct Test and correct Ma...

Page 383: ...t MUSTbe set at zero or bypassed completely to obtain the maximum amperage reading Individual amperage draw can be measured by inserting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Consult Amperage Chart on the next page for normal amp readings Make sure that the wires are properly reconnecte...

Page 384: ...ion at a time Ifthe high amperage reading drops to zero by unplugging the trailer then the short is in the trailer Ifthe amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to improperly adjusted or nonf...

Page 385: ...ailer Brake Wiring Inspect wiring for bare spots fray etc Hub Drum Inspect for abnormal wear or scoring Wheel Bearing Inspect for corrosion or wear Clean and repack Seals Inspect for leakage Replace if removed Springs Inspect for wear loss of arch Suspension Parts Inspect for bending loose fasteners wear Hangers Inspect welds Wheel Nuts and Bolts Tighten to specified torque values Wheels Inspect f...

Page 386: ...ary Circuit Black Terminal 4 Battery Charge IYellow Terminal 9 AuxiliaryCircuit HBrown Terminal 6 Orange Terminal 9 Auxiliary Circuit Blue Terminal 2 Electric Brake 2 t Common Ground White Terminal 1 Tow Vehicle White Terminal 1 I Green Terminal 3 Red Terminal 51 i Black Terminal 4 Yellow Terminal 7 3 O 0 ID 3 3 Orange Terminal Brown Terminal 6 Blue Terminal 2 I Gray Terminal 8 ...

Page 387: ...HTS PIGTAIL DOES NOT OPERATE BRAKES 7 PIN COUPLER 9 PIN COUPLER CLEARANCES TAIL LIGHTS STOP ml LHTURN LJ GROUND O BATTERY CHARGE g STOP RHTURN GROUND Y I STOP LHTURN TtLLUW o AUXILIARY CLEARANCE feX TAIL LIGHTS STOP RHTURN BATTERY CHARGE TRAILER BRAKE AND LIGHT COUPLER OPERATES BRAKES ...

Page 388: ... Unsupported units can fall causing death or serious injury Extended Storage Inspection Procedures Trailer should remain on jack stands during this procedure 1 Remove all wheels and hubs or brake drums Reinstall drum to same spindle and brake from which it was removed 2 Inspect suspension for wear 3 Check tightness of hanger bolt shackle bolt and U bolt nuts of the suspension for correct torque 4 ...

Page 389: ...anufacturer s specs Inspect tires for any damage or wear 8 Inspect lug nuts bolts All should be torqued to spec See Page 17 for specs 9 Check torque of hanger bolt shackle bolt and U bolt nuts on suspension 10 Check that your trailer is towing level Adjust hitch height if necessary to level trailer CUSTOMER SERVICE TRAILER PLANT 39 1902 W SAMPLE ST SOUTH BEND IN 46619 PH 574 312 6425 FAX 574 534 7...

Page 390: ...Spindle Nut 1 14 Spindle Washer 1 06 x 2 00 CD Outer Bearing Cone 02475 Outer Bearing Cup 02420 Rubber Cap Plug 0 Ring Cotter Pin 120 X 1 75 Flanged Wheel Nut 18 Cone Wheel Nut Vie 18 60 Stud yi6 18GR8 Stud y8 18GR8 Brake Hub 865 12 VV BRK 4 75 Pilot Brake Hub 865 Vs 12 y4 BRK 4 75 Pilot Brake Hub 865 Ys 12 BRK 4 75 Pilot Grease Brake Hub 865 Vs 12 BRK 4 75 Pilot Oil Oil Hub Seal Inner Bearing Cup...

Page 391: ...lic Brake Assembly Part Description 336252 Brake Hydraulic 12 25 x 3 38 4 Bolt Left Hand 3362521 Brake Hydraulic 12 25 x 3 38 4 Bolt Right Hand Disc Brake Assembly Part Description 307319 Disc Brake Rotor 865 ya Studs 307318 Disc Brake Rotor 865Studs 286594 Caiiper Mountinq Bracket for 5 Bolt Brake Flange 158797 Caiiper Mounting Bracket for 4 Bolt Brake Flanqe 134421 BrakeCaliper Assembly Includes...

Page 392: ...511 U Bolt 6 8x 7 25 for 3 Tube YZ 179660 Flat Hardened SAE Washer 1 06 ID x 2 00 OD 122088 Double LipGrease Seal 5 200 7 000 170997 Flat USS Hardened Washer 122077 Brake Nut Locking Keps Clear Dich 122081 Castle Nut 1 14 122084 Sealed Wire Connector 182274 Hex Nut Vie 18 GR8 122075 I Cotter Pin 120 X1 75 Rev 08 25 2015 Trailer Axle 8 12K Owner s Manual ...

Page 393: ...t Vie 18x7 25 for 3 tube B 179660 Flat Hardened SAE Washer 1 06ID x2 00OP C 122088 DoubleLip GreaseSeal 5 200 7 000 D 170997 FlatU55 Hardened Washer Vie E 119072 Flange Nut 16 GR5 F 126030 Washer 385 x 68 x 094 G 182274 HexNut i6 18GR8 H 135835 Tap Bolt s 16 x 1 Vi GR5 ZN FTHD ST I 122081 Castle Nut 1 14 J 122075 Cotter Pin 120x1 75 Quantity Trailer Axie 8 12K Owner s Manual ...

Page 394: ...63511 179660 122075 122081 162836 162838 122253 182274 276712 170997 Description U Bolt yi6 18 X 7 25 for 3 tube Flat Hardened SAE Waslier 1 06 ID x 2 00 OP Cotter Pin 120 x 1 75 Castle Nut 1 14 Hex Bolt y2 20x1 50 Lock Washer 14 x 86 x 125 Hex Nut y2 20 HexNut g l6 18GR8 Seal Oil Washer Vie Flat Quantity Trailer Axle 8 12K Owner s Manual ...

Page 395: ...Hub 865 Vs 4 75 Pilot 183168 Idler Hub 865 5 8 4 75 Pilot 183537 Brake Drum 865 83128 Stud 5 8 18 GR8 176321 Flanged Wheel Nut 18 205049 Wheel Clamp Ring for Vs Studs 205048 Wheel Nut 18 90 124287 Outer Bearing Cup Race 10 000 25520 122066 Outer Bearing Cone 10 000 25580 181895 Spindle Washer 1 50 x 3 00 OD 181894 Spindle Nut 1 y2 12 181899 Cotter Pin Va x 2 VV 183805 O Ring ForOil Cap 183772 OilC...

Page 396: ...1935 Electric Brake LH 12 25 x 3 38 7 Bolt 181936 Electric Brake RH 12 25 x 3 38 7 Bolt 330792 Shoe and Lining Kit 12 VV x 3 38 8 000 10 000 1 BRK Part Description 213222 Bral e Hydraulic LH 12 25 x 3 38 7 Bolt 213223 Brake Hydraulic RH 12 25 x 3 38 7 Bolt Description 294061 Disc Brake 865 Studs 7 Bolt Flange Kit for one axle Trailer Axle 8 12K Owner s Manual ...

Page 397: ... Nut 11 Top Lock GR5 122085 Nut 7 i6 20 Hex 122086 Washer x x 11 GA Helical Lock 207576 Bolt 7 16 20 X 1 y2Hex GR5 181895 Washer 1 y2 IDx3 0D 181894 Nut 1 1 2 12 6 Slot Castle GR2 183804 Rubber Plua for 10 000 Oil Ca 183805 0 rinq 3 764ID 4 OD 138 D A 181899 Cotter Pin Va x 2 Va 176692 Seal 2 855 ID x 3 88 OD Unitized Oil Rev 08 25 2015 Trailer Axle 8 12K Owner s Manual ...

Page 398: ...Shaft X4 50 Bore 12 KUnitized Oil Inner Cone Bearing 12 000 3984 Inner Cup Race Bearing 12 000 3920 Drum Mounting Bolt Brake Drum Hub 865 Vs 4 75 Pilot Idler Hub 865 Vs 4 75 Pilot Brake Drum 865 Vs Stud y8 18 GR8 Flanged Wheel Nut Vs 18 Wheel Clamp Ring for W Studs Wheel Nut18 90 Outer Cup Race Bearing 12 000 3920 Outer Cone Bearing 12 000 28682 Spindle Nut 1 Va 12 Cotter Pin y4 x2y4 O Ring For Oi...

Page 399: ... Part Description 297998 Electric Brake LH 12 25 x 5 7 Bolt 12 000 2979981 Electric Brake RH 12 25 x 5 7 Bolt 12 000 330793 Shoe and Lining Kit 12 VV x 5 12 000 1 BRK Disc Brake Assembly Part Description 1 327573 12000 DISC 865 Vs STUDS 7 BOLT FLG Trailer Axle 8 12K Owner s Manual ...

Page 400: ...ck GR5 122085 Nut 20 Hex 122086 Washer x x 11 GA Helical Lock 207576 Bolt 16 20 X 1 Vi Hex GR5 330037 Nut 1 3 4 12 6 Slot Castle GR2 183804 Rubber Plua for 10 000 Oil Ca 183805 0 rinq3 4lD4 0D 138DIA 181899 Cotter Pin lA X 2 y4 295924 Seal 3 125 Shaft X4 50 Bore 12 K Unitized Oil 162836 Bolty2 20X 1 Vi Rev 08 25 2015 Trailer Axle 8 12K Owner s Manual ...

Page 401: ...Notes Rev 08 25 2015 Page 39 Trailer Axle 8 12K Owner s Manual ...

Page 402: ... LCI representative has been provided Any unauthorized useshall void anyapplicable warranty The information contained in this manual issubject to change without notice and at the sole discretion of LCI Revised editions are available for free download from www lci1 com Please recycle all obsolete materials For all concerns or questions please contact Lippert Components Inc Ph 574 537 8900 Web lci1 ...

Page 403: ...c H A R S ...

Page 404: ...any warranty claim it is important that this page be filled out and returned to SKYLIFT INC at the address given below within ten 10 days ofthe delivery date ofthe equipment Fill out form and return to Skylift Model Name Skylifl Serial Number Company Name Address City Contact Name _ Phone Number Email Address SKYLIFT INC ATTN Susan Naso 3000 LEAVITT RD UNIT 6 LORAIN OH 44052 Phone 440 960 2100 Fax...

Page 405: ...ules programs or bulletins b products which have not been mounted in accordance with Skylift installation procedures c products not manufactured by Skylift which are supplied by Skylift d products which are repaired without using original Skylift parts or e transportation or delivery to a Skylift service facility or the customer s location 3 The battery generator hydraulic components electrical co...

Page 406: ...d date Refer to the Skylift DATA TAG on the machine Hours on the equipment Refer to the HOUR METERlocated on he moch ne The reported issue will be evaluated by Skyllft s service department and Skyliftwill work with the technician over the phone to determine the problem and advise on the repairs if needed The Skylift technician will estimate labor hours for the repair as well Skylift MUST provide t...

Page 407: ...e No Email Address Detailed Description of Problem s and if known Cause of Failure Total Cost of Parts Labor Rate Per Hour Total Labor Time Total Labor Charge other Charqes explain Sales Tax If applicable TOTAL of Claim Claim Repair or Work Order No FOR OFFICE USE ONLY BELOW Notes Skylift Inc Authorization WARRANTY CLAIMS will NOT be processed unless there has been prior approval from the factory ...

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