Resle
bobcat
1 of 252
Printed in U.S.A
WRONG
AWARNING Never operate or service 2000 Rough Terrain Forklift (RTF)
without instructions. See Operator's or Service Manual.
Always fasten your seat belt.
Always fasten the seat belt.
A
Keep load low when traveling, turning or changing speed.
A
Load, unload or turn on flat, level ground only.
A
Never exceed capacity.
A
Do not get off the RTF when forks or attachment is up. Stop engine and lock brake before removing seat belt and getting off the RTF.
A
A
When learning to operate, be careful. Go slow.
WRONG
A A A A A
A A
Always use the steering frame lock before working on the
Forklift.
A
WRONG
WRONG
A
A
Use the steering frame lock before working on the loader.
A
Stop and cool engine before adding fuel. NO SMOKING.
rated
load
Always carry the load low. Always carry a load tilted back and against the backrest.
Do not service RTF without using a lift arm stop when lift arms are raised. Keep rear door closed except for service. Stop, cool, and clean engine of flammable material. Keep body, loose objects, and clothing away from electrical contacts, moving parts, hot parts, and exhaust. When connecting extra battery for "jump" start always make the last connection (negative cable) to the engine never at the battery. When removing the "jump" start cables, always remove the negative (-) cable from the engine first. Leaking fluids under pressure can enter skin, cause serious injury and require immediate medical attention.
battery. Battery acid causes severe burns. If acid contacts eyes, skin or clothing flush well with water. For contact with eyes get immediate medical attention. Wear safety goggles. Do not modify equipment or add attachments not approved by
manufacturer. WARNING: Failure to obey warnings may cause injury or death. Never allow riders.
A 2 of 252
exceed
rated operating
Lead acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames, and lighted tobacco away from the
Always lower the vertical mast and shut-off engine before leaving the seat.
Do not capacity.
Do not use steering wheel or control levers for grab handles.
Safety Alert Symbol
A
Do not use Forklift in atmosphere with explosive dust or gases. WRONG
Do not fill the fuel tank with the engine running, while smoking or when near an open flame. ,WRONG
Always use a chain hoist to support the vertical mast when it must be in raised position for servicing.
Resle
A
A A
SAFETY INSTRUCTIONS SAFETY IS YOUR RESPONSIBILITY The Rough Terrain Forklift is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards which are common for off-highway, rough-terrain applications but are not unique for use of the Bobcat Forklifts. The machine has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill so the machine must be used with adequate ventilation. The machine must not be used in space with explosive dusts or gases or so that the engine exhaust contacts flammable material. The machine has a spark arrestor muffler which is required for operation in certain areas. For machine applications, the dealer recommends the capabilities and restrictions of the machine and attachments for each application use. The dealer demonstrates the safe operation of the machine according to the manufacturer's instructional materials which are also available to all operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the machine. For each model machine, the user must check with the dealer or manufacturer's literature to identify each bucket or attachment for safe loads of materials of specified densities. The following publications provide information on the safe use of the machine and attachments: 1
.
The Delivery Report is used
to
check whether complete instructions have been given
to
the new owner.
2. The Operator's Manual delivered with every machine gives operating information as well as routine maintenance and service. 3. Every machine has signs (decals) which instruct on the safe care and operation of the machine. The complete signs and their location are shown in the Operator's Manual. All signs are available from the dealer. 4.
The Bobcat Forklift has a plastic Operator Handbook fastened by cable to the operator cab. It has brief operations always available to the operator. The handbook is available from the dealer in an English edition or a combination English, French, German. Spanish edition.
The dealer and owner/operator review the recommended uses of the machine and attachments at the time of delivery of the machine. If change of the use of the machine occurs in the future, the owner/operator must romember to ask the dealer for recommendations on the new use of the machine.
READ THIS MANUAL BEFORE YOU SERVICE THE BOBCAT ROUGH TERRAIN FORKLIFT (RTF)
AWARNING
All operators must have instruction before operating this loader.
This Service Manual was written to give the service personnel instructions on the safe service of the Bobcat Forklift. READ AND UNDERSTAND THIS SERVICE MANUAL BEFORE YOU SERVICE YOUR BOBCAT.
AWARNING
IMPORTANT
For your safety, warnings are on the loader and in the manual. Failure to follow these warnings can cause injury or
This notice shows important procedures which must be followed to prevent damage to
death.
the loader.
i
3 of 252
2000 RTF Service Manual
Resle
5. The Service Manual and Parts Book are optional manuals from the dealer for use by mechanics to do shop-type service and repair work.
SAFE OPERATION NEEDS A QUALIFIED OPERATOR A QUALIFIED OPERATOR* MUST DO THE FOLLOWING: A.
UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS 1. The written instructions from the Clark Equipment Co., include the delivery report, loader operator's handbook and manual, attachment manual and machine signs (decals). 2.
B.
C.
Check the rules and regulations at your location. The rules may include an employer's work safety requirements. Regulations may identify a hazard such as a utility supply line.
HAVE TRAINING WITH ACTUAL OPERATION 1.
Operator training must consist of a demonstration and verbal instruction. This training is given by the Bobcat dealer before the loader is delivered.
2.
The new operator should start in an area without bystanders and use all the controls until he can control the loader at full use under the conditions for his work area.
KNOW THE WORK CONDITIONS 1.
For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example in handling certain loose materials with a given bucket, he must know whether he can safely take a full or part of a bucket load.
2.
The operator must know any prohibited uses or work areas for the loader. For example, he needs to know about excessive slopes.
Resle
*For an operator to be qualified, he must not use drugs or alcoholic drinks which change his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice on whether or not he can safely operate a machine.
ii 4 of 252
2000 RTF Service Manual
FOREWORD PREVENTIVE MAINTENANCE This manual gives instruction for correct servicing and adjustment of the Bobcat Forklift, and overhaul instructions of the drive system, machine hydraulic/hydrostatic system and general main frame parts.
Make reference to the Operator's Manual for operations instructions (Starting Procedure, Daily Checks, Vertical Mast Operations, etc.).
HYDRAULIC SYSTEM
A general inspection of the following items must be made whenever the machine has had service or repair:
HYDROSTATIC SYSTEM
1 . Check hydraulic fluid level, engine oil level and fuel supply.
2.
Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3.
Lubricate the machine.
4.
Check battery condition and cables.
5.
Inspect air cleaner system for damage or leaks. Check element and make replacement, as needed.
DRIVE SYSTEM
6.
Check electrical charging system.
7.
Check the warning lights.
8.
Check tires for wear and pressure.
9.
Check the attachment for condition. Inspect the vertical mast for damage or wear.
ELECTRICAL SYSTEM
10. Inspect safety items for condition (Operator Enclosure, Seat Belt, Safety Treads, Lights, Horn, Safety Signs [Decals], Brake, etc.).
Make an inspection for loose or broken parts or connections.
1 2.
Operate the Bobcat Forklift, checking all functions.
ENGINE SERVICE
Resle
1 1.
TECHNICAL DATA
Check the above items, if any are in need of repair tell the Owner/Operator.
ALPHABETICAL INDEX
CONTENTS 1
PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM HYDROSTATIC SYSTEM DRIVE SYSTEM
2 3 4 5 6 7
MAIN FRAME ELECTRICAL SYSTEM ENGINE SERVICE TECHNICAL DATA ALPHABETICAL INDEX
8 9
iii 5 of 252
MAIN FRAME
2000 RTF Service Manual
Resle 6 of 252
.
PREVENTIVE MAINTENANCE
...... ......... ......
ADJUSTING THE DOOR LATCH AIR CLEANER SERVICE ALTERNATOR BELT BACK-UP ALARM DELIVERY REPORT ELECTRICAL SYSTEM ENGINE COOLING SYSTEM ENGINE LUBRICATION SYSTEM ENGINE SERVICE FRAME LOCK FRONT & REAR AXLES FUEL SYSTEM HYDRAULIC/HYDROSTATIC SYSTEM .. LIFTING AND BLOCKING THE BOBCAT FORKLIFT LUBRICATION OF THE BOBCAT ROUGH TERRAIN FORKLIFT OPERATOR CAB SERIAL NUMBER LOCATIONS SERVICE SCHEDULE SPARK ARRESTOR MUFFLER TIRE MAINTENANCE U-JOINTS VERTICAL MAST
Paragraph Number
Page Number
1-7 1-8 1-12 1-20 1-4 1-13 1-11 1-10 1-6 1-1 1-15 1-9 1-14
1-4 1-4 1-9 1-21 1-2 1-9 1-9 1-7 1-4 1-1 1-17 1-5 1-14
1-2
1-1
1-18 1-22 1-3 1-5 1-19 1-17 1-16 1-21
1-19 1-21 1-2 1-3 1-20 1-17 1-17 1-21
PREVENTIVE MAINTENANCE
Resle
....... ....... ........ Instructions are necessary before doing service on forkiift. See warnings and instructions both at beginning and throughout this manual. After doing service or making repair or adjustment, always check function of machine.
A WARNING
7 of 252
Safety glasses or goggles are always needed for eye protection from electric arcs from shorts or welding, battery acid, compressed springs, fluids under pressure, and flying debris or loose material when engines are on or tools are used. Failure to obey warnings can cause injury or death.
2000 RTF Service Manual
Resle 8 of 252
1 PREVENTIVE MAINTENANCE 1-1 FRAME LOCK
Before any service or repair work is done on the Bobcat Forklift, always install the steering frame lock (Fig. 1 - 1 ).
A WARNING DO NOT let anyone in or near the pivot area without the steering frame lock installed (Fig. 1-2).
ANIONtSTACION AWARNING WARNUNG AVtRTISSEMtNT
MMMM* ssS&Sb
1-2 LIFTING AND BLOCKING THE BOBCAT FORKLIFT
AWARNING Lift Bobcat and put blocks under the frame so that there is no danger of the machine falling and causing personal 6585904 B-3816 5748
Resle
injury.
.
F'9- 1-1 Installing Steering Frame Lock . Before doing maintenance on the Bobcat Forklift, you must lift it up and block it as follows: „ ,
(1)
Lower the vertical mast. Stop the engine and install the framelock.
(2)
Put a floor jack under the rear of the machine.
WRONG
(3) After the rear of the Bobcat Forklift is lifted, put a jackstand under each rear corner. Make sure the machine is level. (4)
Put the floor jack under the center of the front axle.
(5) After the front of the machine is lifted, place jackstands under each side of the front axle. Make sure the machine is level.
AWARNING
Do not stand on the front wheels. The front wheels will turn freely when the machine is lifted.
B-5753
Fig. 1—2
-1-1i
9 of 252
Pivot Area Warning
2000 RTF Service Manual
1 -3 SERIAL NUMBER LOCATIONS It is important to make correct reference to the Serial Number of the Bobcat Forklift, the vertical mast and/or engine when making repairs or ordering parts. It is possible that the present machines do not use all of the same parts as earlier machines or it is possible that different procedures are used for service or repair.
o
_
©
Always have these numbers available when ordering parts or working on the Bobcat Forklift.
B-5932
ig. 1 -3
Forklift Serial Number
B-5785
Fig. 1-4 Engine Serial Number
1—3.1 Machine Serial Number The Bobcat Forklift serial number is located at the rear of the machine over the rear door (Fig. 1 — 3, Item 1 ). Explanation of the Serial Number:
XXXX
M
XXXX
3075V001 000/8088
Production Sequence (Series)
Factory Model,
Use Only Engine Version
1—3.2 Engine Serial Number The engine serial number is on the right side of the engine, above the injection pump (on the cylinder block) (Fig. 1 —4, Item 1 ).
The vertical mast model/serial number is located on the right side of the outside rail (Fig. 1-5). Explanation of the Model/Serial Number:
XXXX
V XXXXXX
B-5748
Fig. 1-5
Vertical Mast Model/Serial Number
Fig. 1-6
Delivery Report
XXXX
Production Sequence (Series) Model
Size 1—3.4 Axle Serial Numbers
All axles have identification numbers and letters on them. The front axle serial number is located on the left hand tube near the cover, 45° up from the bottom center of the tube. The rear axle serial number is located on the right hand tube near the cover, 45° up from the bottom center of the tube.
1-4 DELIVERY REPORT (Fig. 1-6)
The Delivery Report is to be filled out by the dealer and signed by the owner or operator when the Bobcat Forklift is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely.
-1—210 of 252
2000 RTF Service Manual
Resle
1—3.3 Vertical Mast Serial Number
1-5 SERVICE SCHEDULE
You must do maintenance work at regular intervals. Failure to do so will result in damage to the Forklift or the engine. The service schedule is a guide for correct maintenance of the Bobcat Forklift. Follow this service schedule as explained below unless it is to increase the frequency of intervals when the Bobcat Forklift is used in very hot, cold, dusty or corrosive conditions.
HOURS
SERVICE SCHEDULE
ITEM
SERVICE REQUIRED
8-10
Engine Oil
Check the oil and add as needed.
Engine Air Cleaner
Check the condition indicator. Inspect the air cleaner system. Replace the outer element when the red ring shows in the indicator window.
Tires
Check tires for damage and correct air pressure.
Seat Belt
Check function and condition of the seat belt. Replace
50
100 200
500 1000
if necesary.
Safety Signs (Decals)
Check for damaged decals. Replace any decals that are not in the correct location.
All Pivot Points
Add lubricant to all fittings (See Page 1—19).
Hydraulic Fluid
Check the fluid level and add the recommended fluid as needed.
Engine Coolant System
Check coolant level and add as needed. Remove any debris from the grill area.
ATighten wheel nuts to 1 1 5 ft. -lbs.
(1 55 Nm) torque.
Fuel Filter Water Trap
Remove any trapped water from the filter.
Batteries
Check the battery cables and the water level of the batteries.
*Cylinder Heads
Tighten cylinder head bolts to the correct torque.
Hydraulic Control Lever
Check for correct operation. adjustments as needed.
Pallet- Fork Lock Levers
Check the locking levers for condition and correct operation.
Brakes
Check
Alternator Drive Belt
Check condition and tension of the belt.
Engine Oil & Filter
Replace oil and filter.
Carriage Chains
Check for wear and correct tension. Put oil on chains.
Spark Arrestor Muffler
Empty spark chamber.
Hydraulic Filter
Replace the right hand filter.
U-Joints
Lubricate with a good quality grease.
the brake for correct adjustment as necessary.
(Drive Shaft)
Make repairs and
operation.
Final Fuel Filter
Replace the filter element.
Front & Rear Axle
Check oil level and add oil as needed.
U-Joint (Engine to Hydrostatic
Add grease to fittings (3).
Resle
Wheel Nuts
Make
Pump)
Bronze Filter (40 Micron)
Change the 40 micron filter in the hydrostatic port
block. Hydraulic/Hydrostatic System
*
ÿ
Replace the fluid and filters. Clean the cap and vent.
Dealer Service Only (This procedure is required only once, after the first 50 hours of operation). Check the wheel nut torque every 8 hours for the first 24 hours of operation.
-1-311 of 252
2000 RTF Service Manual
1-6 ENGINE SERVICE
AWARNING Stop, cool and clean the engine of flammable material. Never service or adjust machine with
engine
running
unless
instructed to do so. 1-4101 1-5772
8-3757
Fig. 1 -7
Releasing Rear Door
Fig. 1-8 Adjusting the
Latch
Open the rear door to service the engine. Pull the door latch up and to the left to release the door latch (Fig. 1—7). The door can then be fully opened to get to the engine,
1-7 ADJUSTING THE DOOR LATCH
AWARNING
Keep the rear door closed except for service. Make sure you close the door and fasten the latch tightly before operating the Bobcat Forklift.
8-4099
Fig. 1 -9
Closing the Door
1-8 AIR CLEANER SERVICE It is important to check the air cleaner condition indicator at regular intervals for good engine performance and long service life. Do not service the air cleaner until the red condition indicator ring shows.
NOTE:
Before changing the air cleaner, push the button on the condition indicator (Fig. 1—10, Item 1), start the engine and if the red ring still shows, do the following service procedure.
The large air cleaner element (outer) must be replaced when the red ring shows in the window of the condition indicator (Fig. 1 — 10, Item 1). DO NOT remove the inner filter. Service the air cleaner as follows: -1 -412 of 252
B-6572
Fig. 1-10 Condition Indicator
2000 RTF Service Manual
Resle
Loosen the set screw (Fig. 1 —8, Inset). Turn the nut on the end of the latch pin (Fig. 1 —8). The door must contact the machine at the bottom (Fig. 1 —9, Item 1 ) and the top with the lever in the position shown in figure 1 —9. It will take approximately 50 lbs. of force to push the latch down. When the latch is adjusted correctly, tighten the set screw. The set screw must be aligned with the flat surface of the bolt.
(1) Remove the wing nut (Fig. 1 — 10, Item 2) and remove the air cleaner cover. Remove the filter element (Fig. 1—11, Item 1 ).
(2) Clean the inside of the filter housing (Fig. 1—11, Item 2) so that the element has a smooth surface to contact at the seal. Make sure the air cleaner housing is free of corrosion, especially if the Bobcat Forklift is used under corrosive conditions.
(3)
Install the outer filter element. DO NOT replace the inner filter element (Fig. 1 — 12, Item 3) unless the red ring still shows (after the engine is running) in the condition indicator window after replacing the outer element.
(4)
Install the air cleaner cover (Fig. 1—11, Item 4).
(5) Push the button at the condition indicator, to remove the red ring in the window.
(6) Check that the hoses and the clamps are tight.
u
1-9 FUEL SYSTEM
B-549 1
Resle
Use number 2 diesel fuel in the engine. During very cold temperature conditions, use number 1 fuel.
Air Cleaner Assembly
AWARNING
WRONG
Never add fuel to the Bobcat Forklift when the engine is running or is hot. NO SMOKING (Fig. 1-12).
1—9.1 Fuel System Service
Remove the filler cap to service the fuel tank as follows (Fig. 1—13, Item 1): Use a clean, approved safety container to add fuel.
B-57 5 7
(1)
Fig. 1-12 Fuel Fill Warning
-1-513 of 252
2000 RTF Service Manual
(2)
The key switch must be in the "OFF" position and the engine cool.
(3) Add fuel only in an area that has a free movement of air or no open flames or sparks. NO SMOKING (Fig. 1-12).
__ H
j
/ÿ'/
//
//
ji
III j:i
(4) Use only clean fuel of the correct specifications (See Section 8 for specifications).
v\\>
Tighten the cap on the fuel tank on the right side of the machine (Fig. 1-13, Item 1).
(5)
1-9.2 Fuel Filter The fuel filter is installed at the front left of the engine. Replace the filter element (Fig. 1 — 14) every 200 hours of machine operation.
CO
y\
\
\
B-3827
Fig. 1-13 Fuel Fill Location
Check the water trap every 50 hours of machine operation. If there is water in the water trap at the bottom of the filter, loosen the thumb screw (Fig. 1—14, Item 1 ). When fuel flows from the drain with no water, tighten the thumb screw.
To replace the fuel filter element: (1) Clean the area around the fuel filter. Put a clamp on the fuel supply hose from the fuel tank.
(2) Remove the thumb screw at the bottom of the filter, drain the fuel from the filter.
(4)
Resle
(3) Remove the filter by removing the small bolt at the top of the filter head (Fig. 14, Item 2) while holding the nut below the filter bowl. Remove the filter bowl.
Check the condition of the seals. Replace as needed.
(5) Install the filter, bowl, nut and thumb screw. Tighten the thumb screw finger tight only. Remove the clamp from the fuel line.
(6)
(7)
Remove the air from the fuel system.
\
8-6574
Fig. 1-14 Fuel Filter
After the engine is running, check for leaks.
1—9.3 Removing Air From The Fuel System After replacement of the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine. To remove the air from the fuel system: (1 )
Open the rear door of the machine.
(2)
Open the vent plug on the top of the fuel filter (Fig. 1 — 14, Item 3).
(3) Operate the hand pump (Fig. 14, Item 4) until the fuel flows from the vent plug on the top of the fuel filter (Fig. 1—14, Item 3).
-1-614 of 252
2000 RTF Service Manual
(4)
Close the vent plug on the top of the fuel filter.
(5)
Again operate the hand pump until the hand pump feels solid.
(6)
Loosen the vent pump on the fuel injection pump (Fig. 1—15, Item 1 ).
(7) Operate the hand pump (Fig. 1—14, Item 3) until fuel flows from th$tvent plug with no air bubbles.
Fig. 1-15 Fuel Injection Pump (8)
Close the vent plug on the injection pump before releasing the hand pump.
(9)
Loosen the high pressure tubelines at the fuel injectors (Fig. 1 — 16).
(1 0) Move the throttle to the half open position. Turn the engine with the starter until clear fuel shows at the fittings of the injectors.
NOTE: Turn the engine for 30 seconds only with 60 seconds between starts. B-4330
IMPORTANT
Fig. 1-16 Fuel Injectors
Resle
(11) Tighten the fittings of the high pressure tubelines to 1 5 ft. -lbs. (20 Nm) torque.
When removing the high pressure tubelines from the injectors. DO NOT bend them.
(1 2) Close the rear door.
8-5774
Fig. 1-17 Oil Dipstick
Keep Oil Level Between These Marks
1-10 ENGINE LUBRICATION SYSTEM Check the oil level each day.
To check the oil level, stop the engine, open the rear door and remove the dipstick (Fig. 1-17).
Keep the oil level between the marks on the dipstick (Fig. 1—18). Do not fill above the top mark. Use a good quality motor oil that meets API Service Classification of CC or CD (See the Chart).
-1-715 of 252
A-1 528
Fig. 1-18 Engine Dipstick
2000 RTF Service Manual
1—10.1 Replacement Of Engine Oil And Filter
The original oil fill at the factory is 5W-30 engine oil. Replace the engine oil and filter every 50 hours of machine operation.
RECOMMENDED SAE VISCOSITY NUMBER OILS FOR ENGINE CRANKCASE)
(LUBRICATION
C° -34 -29
-23
-18 -13
-7
-1
+4 +10 +15 +21 +27 +32 +38
SAE 10W-30/40 B-5775
If>
SAE 15W-40
Fig. 1-19 Engine Oil Drain
SAE 5W-30
SAE 30
iisj SAE 20W/20
$
SAE 10W PI-2358
F° -30
-20
-10
0 +10 +20 +30 +40 +50 + 60 +70 +80 +90 +100
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL: USE API
CLASSIFICATION CC) Fig. 1 -20
Engine Oi! Filter
To replace the engine oil and filter, use the following procedure:
(2)
Remove the drain plug at the end of the hose (Fig. 1—19, Item 1).
(3)
Remove the oil filter (Fig. 1 —20).
Resle
(1) Run the engine until it is at operating temperature. Stop the engine and open the rear door.
B-5777
Fig. 1—21 Engine Oil Fill (4)
Clean the filter housing surface. Put grease on the gasket of the new filter element. Install the filter element and hand tighten only.
(5)
Install the drain plug (Fig. 1—19).
(6) Remove the oil fill cap and put in 7.5 qts. (7 L) of oil (Fig. 1 — 21 ) (See the Oil Chart).
(7) Start the engine let it run for several minutes. Stop the engine and check the oil level (Fig. 1—18). Add oil if the level is not at the top mark on the
dipstick.
-1-816 of 252
2000 RTF Service Manual
1-11 ENGINE COOLING SYSTEM
Coolant Level The cooling sytem has a coolant recovery tank. The location of the tank is behind the rear door and in the left upright (Fig. 1—22). Remove the cap from the tank to check the coolant level. When the engine is cool, the coolant recovery tank must be 1/3 full. Add coolant to the tank when the coolant level is low.
1— 11.1 Removing Coolant From The Cooling System
Clean the cooling system once a year. The complete cooling system must be drained, flushed and refilled with clean coolant.
-3826
Fig. 1-22 Coolant
Recovery Tank
Remove the rear grill from the machine. Remove the radiator cap from the radiator. Install a hose on the engine block drain (Fig. 1 —23, Item 1) and open the drain to remove the coolant from the system.
After the coolant is removed, remove the hose and close the engine block drain. Fill the radiator to the top of the fill pipe with premixed coolant and install the radiator cap. Install the rear grill.
NOTE:
Protect the cooling system from freezing temperatures by adding premixed 50/50 ethylene glycol (anti-freeze) and water to the system.
Starter .-4256
Remove the cap from the coolant recovery tank (Fig. 1—22) and fill the tank 1/ 3 full of premixed coolant.
Fig. 1-23
Engine Coolant Drain
Resle
1-12 ALTERNATOR BELT To adjust the belt tension, use the following procedure:
(1)
(2) set
Remove the belt shield (Fig. 1 —24).
Loosen the adjustment bolt (Fig. 1—25, Item 1 ) and move the alternator to the belt tension at .28-. 35" (7-9 mm) at 1 3 to 1 5 pounds of force.
B-5782
Fig. 1-24 (3)
Tighten the adjusting bolt at the alternator.
(4)
Install the belt shield.
Removing Engine Shield
1-13 ELECTRICAL SYSTEM
The Bobcat Forklift has a 12 volt, negative ground alternator charge system (Fig. 1 -26 & 1-27).
The electrical system is protected by two (2) fuses. The fuses are located on the dash panel (Fig. 1 —26). The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again. Look for an open wire or a short in the electrical system. -1-917 of 252
b-t> /H3
Fig. 1-25
Checking Belt Tension
2000 RTF Service Manual
OPERATOR GUARD WIRING DIAGRAM 2000 RTF
J G
/
»-17F
COLOR
1 2 3 4 5 6 7 8 9 10 11 12 13
Purple U. Blue/Black White/Orange Lt. Green/White White/Orange Purple/White Black Not Used Not Used Not Used
Pink Red/Black
16 12
Orange/Green
14
Yellow/Brown
15 16
Orange/Ok. Blue Yellow/Green Black Black Black
16 16 16 16 12 16
17 17A 17B 17C 17D 17E
17F 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34
Black
Black Black Black
Yellow/Black Orange/Black Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange
Brown Dk. Blue Dk. Blue Pink Dk. Blue/White
16
16 16 12 16 16 16
COLOR
GAUGE 16 18
37 38
Red/White Red/White Red/White Yellow/Black
39 40 41 42
18 16
Grey Grey Grey
35 36
43 44 45
Red/White
Brown Brown Orange/Black
16 18 18 18 18 16 16 16 16 16 16 16 16 18 18 18 18 16 16 16
16 16
18
18 18 18 16 16 16
38)27
ÿ9 Harness Connector
0
32,30
19i 37i36
PARTS LEGEND
"ear Wiper (Opt.)
ÿ Back-Up Alarm ÿ9 Hear Lamp ÿ9 Tail Lamp
0 Accessories (Fused & Switched) 0 Left Flasher Lamp (Opt.) 0 Left Front Lamp 0 Front Wiper
0 Ignition Switch 0 Hourmeter 0 Shut-Down Module (Opt.) 0 Time Delay Switch 0 Operator Guard Ground
• Tee Butt
Resle
WIRE LEGEND GAUGE #'S
#'s
39 j 12,35 21 16,27
14,25
11 ,13il5tl7
Splice
O
Splice
ÿ9 Flasher (Opt.)
© Right Front Lamp © Right Flasher Lamp (Opt.)
ÿ9 Engine Temperature Gauge
© Fuel Gauge Light Switch
© Wiper Switch "Trans" Warning Lamp
0 0 Accessory Switch (Opt.) 0 Fuse (Accessory) © Fuse (Ignition) 0 Voltmeter "Eng" Warning Lamp
E- 1 427
Fig. 1-26 Operator's Guard Electrical Circuitry
-1-1018 of 252
2000 RTF Service Manual
ENGINE WIRING DIAGRAM 2000 RTF
Resle
TRANSMISSION
ENGINE
WIRE LEGEND #'s 1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
17A 18 19 20 21 22 23 24 25 26
27 28 29
COLOR Purple Lt. Blue/Black
Red Lt. Green/Wkite White/Orange Purple/White Black Not Used Not Used Not Used Pink Red/Black Orange/Green Yellow/Brown Orange'Ok. Blue Yellow/Green
Black Black Yellow/Black Black OrangelDk. Blue Black White Red WhiteLt. Green Lt. Blue/Yellow Yellow/Black Red Lt. Green Cable
GAUGE 16 16 12 12 16 16 16
16
#'s
COLOR
30 31 32 33 34 35 36
Cable Lt. Blue/Orange White/Black Cable Cable Cable Orange
GAUGE 8 16
12
Q Harness Connector Q Chassis Power (Fused & Switched) Q Horn Switch Q Horn Q Neutral Start/Back-Up Alarm Switch
o
12 16 16 16 16
12 16 16 16 16 16 16 12
ÿ Battery
ÿ Frame Ground Fuel Sender
Fuel Shut-off
• Tee Splice
Hydraulic Filter Pressure
o Butt Splice
Hydraulic Oil Temperature
Q Engine Oil Pressure Starter
Q Glow Plugs Engine Coolant Temperature
12 16 16 12 16
© Start Relay
Alternator
ÿ Diode (2) ÿ Glow Plug Relay E- 1 426
Fig. 1-27 Engine Electrical Circuitry
19 of 252
-1-11-
2000 RTF Service Manual
To service the electrical system: ( 1)
Check that the battery cables are clean and tight and check the water level of the batteries. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate (baking soda) and water solution (Fig. 1 —28). Cover the terminals with Clark Battery Saver to prevent corrosion.
Water and Baking Soda
Solution
(2) Check the tension of the alternator belt (See figure 1 —25 for the correct belt adjustment). (3)
Make sure that all wire connectors are tight.
(4)
Check for broken or open wires.
A-27 4 1
(5) Two (2) 25 ampere fuses are installed in the dash panel. If the fuses become damaged, replace them with the same type and size fuses.
NOTE:
Fig. 1-28 Cleaning the Battery
The "ENG" warning light and the transmission light will come "ON" when the key switch is turned "ON". When the engine is started the engine light must go "OFF". If it does not go off, stop the engine and find the problem. The transmission light will go off after a time of 4 to 8 seconds.
1 —1 3.1 Using An Extra Battery (Booster Starting)
Resle
AWARNING
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from battery. When using an extra battery to "jump" start an engine, make connections as recommended in manual. When connecting extra battery for "jump" start always make last connection (negative cable) to engine (never at battery). When removing "jump" start cables, always remove negative cable from engine first. Never charge frozen battery.
If it is necessary to use an extra battery to start the engine, BE CAREFUL! This is a two (2) person operation. There must be one person in the operator's seat and one person to connect and disconnect the battery cables.
AWARNING
Lead-acid batteries contain sulfuric acid which will damage the eyes or skin on contact. Always wear goggles to avoid acid in the eyes. If acid contacts eyes, wash immediately with much clean water and get medical attention. Wear rubber gloves and protective clothing to keep acid off the skin. If acid contacts the skin, wash off immediately with clean water.
(1)
The ignition must be in the off position.
(2)
The battery to be used must be of the same voltage.
(3) Battery terminals have identification marks. The positive terminal is marked (+) and the negative terminal is marked ( — ). (4)
The negative terminal ( — ) of the battery must be connected to the engine.
-1—1220 of 252
2000 RTF Service Manual
AWARNING Connected to DO NOT charge a frozen battery because it can explode and cause personal injury. Let the battery warm to 60°F (15.5°C) before connecting to a battery charger.
the Starter
Forklift Battery
(5) Connect the end of the first cable to the positive terminal ( + ) of the booster battery. Connect the other end of the same cable to the positive terminal ( + ) of the machine battery (Fig. 1 —29).
NOTE:
Figure 1—29 does not show the batteries as they are located in the machine.
MACHINE BATTERY
Booster
Cables
(6)
Connect the end of the second cable to the negative terminal ( — ) of the booster battery. Connect the other end of the second cable to the engine. DO NOT connect the cable directly to the negative terminal ( — ) of the machine battery. Connecting the cable directly to the negative Fig. 1-29 Connecting the Extra Battery terminal ( — ) of the machine battery can cause a spark and destroy the battery and cause personal injury. (7)
EXTRA BATTERY Connected to the Engine for Ground C-2575
Keep the cables away from the fans and belts.
(8)
Start the engine.
(9)
After the engine has started, remove the cable connected to the engine.
(10)
(+>.' (11)
Resle
NOTE: The operator must be in the operator's seat and have the seat belt fastened.
Then remove the cable from the machine battery post positive terminal install the rubber covers over the battery terminals.
Damage to the alternator will occur if:
1. The engine is operated with battery cables disconnected.
IMPORTANT
2. The cables are connected when using a fast charger or when welding on the Bobcat Forklift (Remove both cables from the battery).
3. The extra battery connected wrong.
cables are
1— 13.2 New Battery Installation (1) Remove the battery cables (negative cable first) (Fig. 1 —30). Remember the position of the positive terminal and the negative terminal so you can connect the cables correctly after the new battery is installed.
-1 21 of 252
— 13-
B-3709
Fig. 1-30
Removing the Cable
2000 RTF Service Manual
(2) Remove the batteries' hold down clamps (Fig. 1—31). Remove the batteries from the engine compartment.
Clean the terminal posts (Fig. 1—32) of the new batteries. Install the batteries in the engine compartment. Install the hold down clamps.
(3)
NOTE:
DO NOT touch the battery terminals with any metal.
Install and tighten the battery cables. Connect the ground (negative) cable last to prevent sparks.
(4)
8-5879
NOTE:
If one battery needs replacement, you must replace both batteries.
Fig. 1-31
Location of Batteries
1-14 HYDRAULIC/HYDROSTATIC SYSTEM (Fig. 1-33)
The hydraulic and hydrostatic systems use the same hydraulic fluid reservoir..
The system has a vane pump that supplies hydraulic fluid to the control valve and the lift and tilt cylinders.
Resle
Fluid also goes from the control valve to the oil cooler.
There are two (2) filters (one #10 micron and one #3 element) installed in the system. They are in the engine compartment. One is located on the fluid reservoir tank (Fig. 1—34, Item 1 ) and the other is under the air cleaner (Fig. 1 -35, Item 1 ).
The location of the oil cooler is above the engine. The oil cooler is used for cooling the hydraulic/hydrostatic fluid.
1— 14.1 Hydraulic/Hydrostatic Fluid Reservoir
Use only recommended fluid in the hydraulic/hydrostatic system (See Section 8 for the correct fluid to use).
B-3707
Fig. 1
Cleaning the Battery Terminals
-1-1422 of 252
2000 RTF Service Manual
2000 ROUGH TERRAIN FORKLIFT HYDRAULIC & HYDROSTATIC CIRCUITRY
T
/-V
/©
.
T
..
€)
0 STEERING CONTROL VALVE 0 STEERING CONTROL CYLINDER 0 HYDROSTATIC PUMPS PUMP (Vane), 21.5 GPM (81 L/m) O HYDRAULIC @2600 RPM (Governor RPM) RELIEF VALVE, 2000 PSI (13790 0 STEERING kPa) 0 ORIFICE 0 FILTER, 40 micron 0 PORT BLOCK DIVIDER VALVE, 7.3 GPM (27,6 Urn) to 0 FLOW Steering 14.2 GPM (53,7 L/m) to Hydraulics 0 BY-PASS VALVE, 120 PSI (827 kPa) WEATHER 0 COLD (2069 kPa)
BY-PASS VALVE, 300 PSI
© TILT CYLINDERS 0 LIFT CYLINDER 0 FLOW RESTRICTOR 0 COUNTERBALANCE VALVE 0 PORT RELIEF, Lift Cylinder 500 PSI (3448 kPa) © LOAD CHECK —
Fig. 1 33
..-j
- -i
V 's 1"~
-
©
o o
0 MAIN RELIEF VALVE, 2450 PSI (16893 kPa) 0 MANIFOLD BLOCK 0 ORIFICE © HYDRAULIC CONTROL VALVE © SERVO-CONTROL VALVE RESERVOIR, 11 gals. (45 L) Capacity: © FLUID 7 gals. (26 L) Working Capacity 0 TEMPERATURE (104-111°C)
SWITCH, 220-232°F
0 FILTER, 10 micron 0 FILTER BY-PASS, 30 PSI (207 kPa) 0 FILTER, #3 element SWITCH (Differential), 19 PSI 0 PRESSURE (131 kPa) 0 FILTER BY-PASS, 25 PSI (172 kPa) 0 OIL COOLER 0 HYDROSTATIC MOTOR
....... ...... ..... ----
CO REDv CD BLUE CZ1 GREEN CD ORANGE
Hydraulic/Hydrostatic System
1-15 23 of 252
G
/
Resle
©
High Pressure
Low Pressure Case Drain & Reservoir Charge Pressure
E-1425
2000 RTF Service Manual
1 — 14.2 Checking and Hydraulic/Hydrostatic Fluid
Adding
To check and/,or add fluid, use the following procedure: (1) Put the Bobcat Forklift on a level surface.
(2)
Put the vertical mast fully
down. (3) Remove the dipstick and check the level of the fluid (Fig. 1 — 34, Item 1 ). 8-61 03
If the level is below the Fig. 1-34 Filter Location bottom mark (Fig. 1 —36), add the correct fluid (See Section 8 for the correct fluid), until the level of the fluid is at the top mark (Fig. 1 —36). (4)
Fig. 1 -35
Filter Location
Keep Oil Level Between These Marks
(1 )
Remove the drain plug (Fig. 1 —37).
(2)
Put a container under the reservoir (Fig. 1 —38) and remove the fluid.
(3)
When all the fluid is out, install the plug and tighten.
(4)
Remove the oil fill cap/dipstick from the reservoir (Fig. 1 —34, Item 1).
Resle
1 — 14.3 Removing the Hydraulic/Hydrostatic Fluid
(5) Fill the reservoir to the top mark (Fig. 1—36) on the dipstick with the correct fluid (See Section 8 for the correct fluid).
Fig. 1 -36
Fluid Dipstick
—
1 14.4 Replacement of the Hydraulic/ Hydrostatic Filter Replace the right hydraulic filter (10 Micron) every 100 hours of machine operation or more often if necessary.
Replace the left hand filter (#3 Element) when the transmission light stays on for more than 5 minutes after cold start up.
To replace the hydraulic filters, use the following procedure: (1) Clean the area around the filter housings.
(2) Remove the filter elements (Fig. 1 -34, Item 2 & Fig. 1-35, Item 1) with a filter wrench.
Fig. 1-37
Removing Drain Plug
-1-1624 of 252
B-4022
B-4023
Fig. 1-48 Removing the Fluid
2000 RTF Service Manual
(3! Clean the surface of the filter housing head where the filter element makes contact with the filter housing.
(4)
Lubricate the rubber gasket on the filter element with grease.
(5)
Install the filter element. Tighten the filter elements by hand only.
(6)
Check for leaks after you. operate the machine.
o
B-5884
—
1-15 FRONT AND REAR AXLE
Fig. 1 39
Front Axle Check Plug
The final drive of the Bobcat Forklift is the front and rear axles. The rear axle has a limited slip differential and the front axle has a standard differential.
NOTE:
The rear axle must have limited slip additive (GM Part No. 1052358) added to the new oil when the oil is drained and replaced.
Check the oil level in the front and rear axle every 200 hours. When the level is low, put in SAE 90 weight oil.
(1) Put the Bobcat Forklift on a level surface, lower the vertical mast and stop the engine.
B-3828
Fig. 1-40 Rear Axle Check
Plug
Remove the check plug on the covers of the axles (Fig. 1—39, Item 1 and Fig. 1 —40, Item 1). (2)
(3) The oil must be at the check plug hole. If it is not, add the correct oil through the check plug hole until it flows from the check plug hole. Add limited slip additive (GM P/N 1052358) to the rear axle.
(4)
Install the plug and tighten.
1-16 U-JOINTS The drive shaft connects the two axles together. There is a U-joint at each end of the drive shaft (Fig. 1 — 41 ). Lubricate the U-joints with high impact grease (Clark Part Number 6599719 or equivalent grease) every 100 hours (See the Parts Manual for the correct grease).
-1-1725 of 252
B-3874
Fig. 1—41 u-Joint
2000 RTF Service Manual
Resle
To check the front and rear differential oil level, use the following procedure:
1-17 TIRE MAINTENANCE Check the tires regularly for wear, damage and correct tire pressure (See Section 8 for correct specifications).
1— 17.1 Tire Rotation When two tires become worn more than the other two tires, put the two worn tires on the front or rear of the machine. The front tires must be moved to the rear and the rear tires to the front to keep the tire wear even.
AWARNING
Always keep the same size tires on the same axle. If different sizes are used on the same axle, each tire will be turning at a different speed. This will cause excessive wear on the limited slip differential, the pinion and the spider gears in the axles. When a tire wears, always install two (2) new tires on the same axle. The tread bars of all the tires must move in the same direction.
Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Tire pressure must be checked regularly. The operating pressures are listed under machine specifications for the recommended tire sizes. Tires are sometimes inflated above or below operating pressure for shipping. Check for the correct pressure before operating the machine.
AWARNING
Resle
If the tires are changed on the rims, it is important during mounting to avoid excess pressure which can cause rupture of the tire with serious personal injury. During inflation of the tire, check the tire pressure frequently with a tire pressure gauge to avoid over inflation.
Tires must not be inflated above recommended pressure to avoid explosion of the tire which can cause serious injury.
Before the tire is mounted, the rim must be cleaned and free of rust. The tire bead and rim flange must also be lubricated with a rubber lubricant before mounting the tire on the rim to avoid damage to the tire and rim.
1-17.2 Wheel Nuts Check the wheel nuts for correct tightness every 8 hours during the first 24 hours of machine operation and then every 50 hours after that.
Correct torque is 1 1 5 ft. -lbs. (1 55 Nm) torque.
IMPORTANT
DO NOT put fluid in the tires on this
Bobcat Forklift.
-1-1826 of 252
2000 RTF Service Manual
C-2700
Fig. 1-42 Lubrication Chart
1-18 LUBRICATION OF THE BOBCAT ROUGH TERRAIN FORKLIFT
Ref. No.
.
Grease Fittings Engine Oil Dipstick Engine Air Cleaner
4. 5. 6. 7. 8. 9.
Engine Coolant Hydraulic Reservoir Fuel Tank Fuel Filter Engine Oil Filter Hydraulic Filters
10. 11 12. 13. 14. 1 5.
Service Required
Hours
Lubricate with a good quality grease. Check the oil and add as needed. Replace the element when the red ring shows in the Condition Indicator window. Check coolant and add as needed. Check fluid and add as needed. Add Fuel. Remove trapped water. Change oil and change filter. Install new right filter (10 Micron) elements. (Replace left filter #3 element when light comes "ON"). Lubricate with high impact grease. Lubricate with oil. Check oil and add as needed. Lubricate with high impact grease. Lubricate with high impact grease. Drain and put in new fluid.
8-10 8-10
Service Points
1 2. 3.
U-joints Carriage Chains Front & Rear Axle Strg. Cyl. & Rear OSC Joint U-joints (Engine & Hydrostatic) Hydraulic Reservoir
-1-1927 of 252
Resle
Never lubricate, add oil or do any maintenance work with the engine running. If the attachment must be raised in order to do maintenance work, support the lift carriage with chains or other supports.
8-10 8-10 8-10 Daily 50 50
100 100 100 200 200 200 1000
2000 RTF Service Manual
Lubricate the Bobcat Forklift as specified in the Service Schedule on page 7 for the best performance of the machine.
See figure 1 — 42 for the location of the grease fittings. Always use a good quality high impact grease (Clark Part Number 6599719 or equivalent) when you lubricate the Bobcat Forklift. Apply the lubricant until the extra grease shows. Lubricate the seat rails for easy movement when you adjust the seat (See Parts Manual for correct grease).
1-19 SPARK ARRESTOR MUFFLER
This machine is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler.
IMPORTANT
Maintenance on this spark arrestor muffler is necessary to keep it in working condition. Spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.
-3875
Fig. 1—43
Spark Arrestor Muffler Plug Location
If this machine is operated in California on flammable forest, brush or grasscovered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442, PRC.
Make reference to local laws and regulations for spark arrestor requirements.
The spark arrestor muffler must be cleaned every 100 hours of machine operation.
Resle
To clean the spark arrestor muffler, use the following procedure:
A WARNING
Engine must be cool before cleaning spark arrestor muffler. Wear safety goggles.
(1)
Open the rear door.
(2)
Remove the plug at the bottom of the muffler (Fig. 1 —43, Item 1 ).
AWARNING
DO NOT run engine in a space with explosive dusts, gases or flammable material near exhaust.
(3) Start the engine and run it about 10 seconds. Hold a piece of wood over the exhaust outlet to force exhaust gases through the muffler plug.
(4)
Stop the engine and install the plug and tighten it.
(5)
Close the rear door.
-1-2028 of 252
2000 RTF Service Manual
1 -20 BACK-UP ALARM The Bobcat Forklift is equipped with a back-up alarm.
Check for correct operation of the back-up alarm. Start the engine and move the machine backwards. The back-up alarm must come on.
1-21 VERTICAL MAST The Bobcat Forklift has a single-stage vertical mast (upright). The lift cylinder for the vertical mast is offset to the right of the upright. Two (2) tilt cylinders are connected between the vertical mast and the front main frame of the machine. Two (2) carriage chains and a roller system control raising and lowering the vertical mast. Lubricate the carriage chains and rollers with oil every 100 hours. After the first 25 hours of machine operation, tighten the eight (8) mounting frame bolts (Fig. 1 —44, Item 1) again to 300 to 330 ft. -lbs. (407 to 447 Nm) torque.
B-6260
Fig. 1—44
Mounting Bolts
1-22 OPERATOR CAB The Bobcat Forklift has a roll over protective structure (ROPS) as standard equipment and it also protects the operator from falling objects (FOPS).
Never change the operator cab by welding, grinding, drilling holes or adding attachments that are not approved. This can weaken the operator cab and cause personal injury or death. DO NOT make installations on the operator cab that have not been approved by the Engineering Department, Clark Equipment Co., Melroe Division, Bismarck, ND 58501.
Resle
Check with your authorized dealer if the operator cab has been damaged.
-1 —2129 of 252
2000 RTF Service Manual
Resle 30 of 252
HYDRAULIC SYSTEM
OIL RESERVOIR STEERING CONTROL VALVE TROUBLESHOOTING
Number
2-9 2-6 2-10 2-8 2-3 2-1 2-4 2-7 2-5 2-1 1 2-2
2-20 2-8 2-20 2-15 2-3 2-1 2-4 2-13 2-7 2-30 2-2
AWARNING
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
AWARNING
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or damage eyes. Leaks of fluids under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use bare hand. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical attention.
HYDRAULIC SYSTEM
Resle
COUNTERBALANCE VALVE HYDRAULIC CONTROL VALVE HYDRAULIC CYLINDERS HYDRAULIC PUMP HYDRAULIC SYSTEM INFORMATION . HYDRAULIC SYSTEM OPERATIONS . . HYDRAULIC SYSTEM SERVICE MAIN HYDRAULIC RELIEF VALVE . . .
Page
Paragraph Number
2000 RTF Service Manual 31 of 252
Resle 32 of 252
Deal
HYDRAULIC FLOW CHART (6566660) (Printed May 1983)
33 of 252
bobCClt
2000 RTF Starting At S/N 15001
Deal
Q STEERING CONTROL VALVE
© STEERING CONTROL CYLINDER
o
HYDROSTATIC PIMPS
0 MANIFOLD BLOCK
0 HYDROSTATIC MOTOR 0 HYDRAULIC CONTROL VALVE
PUMP (Vane|, 21.5 GPM (81 Um\ O HYDRAULIC 0 SERVO-CONTROL VALVE @2000 RFM |Governor RPM| [Combined Flowl RESERVOIR, 11 gals- 145 U Capacity: 0 FLUID RELIEF VALVE, 2000 PSI [13790 7 gals. (26 L) Working Capacity © STEERING kPa] SWITCH. 2Z5-232*F 0 TEMPERATURE (10+-111°C[ © ORIFICE 0 FILTER, 40 micron 0 FILTER, 10 micron © PORT SLOCK 0 FILTER BY PASS, 30 PSI (207 kPal DIVIDER VALVE, 7.3 GPM 127.6 Um] to 0 FILTER, ft 3 Element O FLOW Steering 14.2 GPM (53,7 Dm] to Hydraulics SWITCH [Differential], 19 PSI 0 PRESSURE [131 kPaf 0 BY-PASS VALVE, 120 PSI [827 kPa} WEATHER BY-PASS VALVE, 300 PSI 0 0 FILTER BY-PASS, 25 PSI (172 kPa] w COLD (2069 kPa] AUXILIARY PORTS 0 CYLINDERS TILT 0 0 UFT CYLINDER High Pressure RED BLUE Low/ Pressure 0 FLOW RESTRICT0R CREEN Case Drain & Reservoir ORANGE -- - -Charge Pressure 0 COUNTERBALANCE VALVE 0 OIL COOLER 0 LOAD CHECK 0 MAIN RELIEF VALVE, 2450 PSI [16893 KPa] 34 of 252
....... .....
FnaM & U4-*
Sb/
hydraulic system explanation
2000 RTF Starting at S/N 15001 Use With Chart 6566660
bobcat
(Printed May 1983)
The fluid flows from the reservoir on top of the hydraulic pump
weather
by-pass
valve
©the
© to the port block © which is
. The
return
by-pass
fluid from the cold
valve
© and
the
oil
0 join the reservoir fluid to supply fluid the hydraulic pump © . "Case Drain" fluid from the hydrostatic pumps © flows from the hydrostatic pumps O through the 10 micron filter © and back the reservoir © . cooler
to
to
© is a "vane type" pump and is driven hy shaft through the hydrostatic pumps © . The fluid goes from the she hydraulic pump to the hydraulic control valve O and steering control valve © . The steering control valve © controls the operation of the steering cylinder © . When the steering valve © is actuated, the fluid goes The hydraulic pump
-1
llllll/IIIIWI
. As
to either the base end or the rod end of the steering cylinder
the fluid goes to one end of the steering cylinder
© the return fluid
comes from the opposite end of the cylinder to the steering control the steering © . When there is enough fluid flow control valve © the priority valve sends the excess fluid flow the hydraulic control valve © The hydraulic control valve 0 has an adjustable relief valve 0 The hydraulic relief valve 0 opens when the pressure gets high, valve
to operate
to
too
releasing the pressure and protecting the system. The fluid that is released, returns to the oil cooler. The auxiliary section of the control valve is non-functional. When the
lift and tilt section spools are in the neutral position, the fluid goes
0 and the ft 3 element 0 and back to the block © . During cold weather operation the fluid will open the cooler by-pass valve 0 and the fluid will flow to the hydraulic pump inlet © . through
the
control
valve
0,
oil
cooler
port
65666G0I6-83M2.5C
35 of 252
Printed «i U.S.A.
Resle
to
So
there
is enough
pressure to
operate
the
control
servo
© a orifice © is installed in the charge pressure line the hydrostatic pumps O . This causes higher pressure in the block the servo control cylinder ©for and in the line cylinder
to
port
to
operation of the servo cylinder.
is a HI/LO combination pump. Two pairs of
The hydrostatic pump
the high pressure hoses go from the center section of the hydrostatic pumps
© to the hydrostatic
motor
© mainifold block © . When
the demand on the hydrostatic system is heavy and low speed, only
one hydrostatic pump
© is providing fluid for the system. When the
demand is light and fast travel speed, both hydrostatic pumps provide
fluid flow to the hydrostatic
motor
©
When the foot pedal is in neutral, the hydrostatic pumps hydrostatic motor
© are
not
and the
working but do have charge pressure.
When the foot pedal is moved, the swashplates are angled and the fluid is forced out of the pressure side of the hydrostatic pumps
.
This fluid flow is called "drive pressure fluid". Drive pressure fluid is much higher than charge pressure fluid which causes the replenishing valves
to
close allowing the flow of the fluid
hydrostatic motor
to
go to the
© . There is a shuttle valve © which moves,
depending on the direction of the machine, and allows fluid to return to the "Tee" at the center section of the hydrostatic pumps
and to
© for cooling. The shuttle valve © opens the charge pressure side of the loop to the stroked charge relief valve © which is located in the manifold block © on the hydrostatic motor © The relief valve © releases the flow when cooling is required in extra
forward or reverse direction. When the machine is driven, with the vertical mast down, into a solid
object there is resistance causing high fluid pressure in the drive loop.
©
{one for forward There are two high pressure drive relief valves and one for reverse) installed in the manifold block of the
hydrostatic motor pressure
©.
These relief valves
from the drive loop to
There is a
tow
valve
protect
©
©
release the high
the hydrostatic system.
© located on the manifold block © of the
© .When the machine is unable to move with its own drive system, the valve © 1/4 push the high pressure relief valves so that the machine can be © off their hydrostatic motor
turn
tow
turn to
seats
moved for a short distance at a low speed.
-2-1A36 of 252
Resle
the oil cooler
Deal
HYDROSTATIC FLOW CHART (6566661) Forward Position
bobcat
2000 RTF Starting At S/N 15001 (Printed May 1983)
f ÿ
o
t
>
37 of 252
[)«9
nuMin"
'3-1'
Deal
A
0STEERING
CONTROL VALVE
0 HYDROSTATIC PUMP A
0REPLENISHING VALVES, 10 P$1 (69 kPa)
0
w FLUID RESERVOIR. 11 gals. (45 L| Capacity: 7 gals. (26 L) Working Capacity
SWITCH, 225-232° F 0TEMPERATURE (104-111° CJ
0FILTER, 10 micron T © FILTER BV-PASS, 30 PSI (207 kPa) HYDRAULIC PUMP (Vane}, 21,5 GPM (Bl,3 L/ra}
O CHARGE
0
(ft
RELIEF VALVE, 225 PSI (1551 kPa]
2600 RPM (Governor RPM} [Combined Flow}
© FILTER,
Element
RELIEF VALVE, 2000 PSI [13790 © (Differential), 19 PSI (131 0STEERING w PRESSURE SWITCH kPa) KPa) 0ORIFICE © FILTER BY-PASS, 25 PSI (172 kPa) 0FILTER, 40 micron © OIL COOLER 0PORT BLOCK 0 HYDROSTATIC MOTOR WEATHER BY PASS VALVE, 300 PSI w CHARGE RELIEF VALVE, 185 PSI 0COLD ©STROKED [1275 kPa} 12069 kPa] Q BY-PASS VALVE, 120 PSI [827 kPa] © MANIFOLD BLOCK DIVIDER VALVE, 7.3 GPM (27,6 Urn) to © HIGH PRESSURE RELIEF VALVE, 4500 PSI 0FLOW Steering 14.2 GPM [53,7 L/m) to Hydraulics (34475 KPa) 0SHUTTLE VALVE ©TOW VALVE ©HYDRAULIC CONTROL VALVE High Pressure CO RED 0MAIN RELIEF VALVE, 2450 PSI (344B kPa) ÿH BLUE Low Pressure VALVE
I ) GREEN EZZ3 ORANGE
Case Drain & Reservoir
- - - - Charge Pressure 38 of 252
— ©SERVO-CONTROL
...... -----
bobcat
HYDROSTATIC SYSTEM EXPLANATION 2000 RTF Starting at S/N 15001 Use With Chart 6566661 (Printed May 1983)
The hydrostatic system has a tandem pump, engine driven, variable displacement
pump
Q which
displacement hydrostatic motor
provides
fluid
flow
to
a fixed
©
Engine RPM is adjustable by a throttle control and is constant.
Machine speed and direction of travel is controlled by a fool pedal which adjusts the amount and direction of fluid flow from the hydrostatic pumps
to
installed in
. Fluid goes through the port block
and to the
section of the hydrostatic pumps
center
© . Fluid from the
goes to the 40 micron filter
steering control valve the port block
the hydrostatic motor
Q . This
fluid is called
"charge pressure fluid". In the center section of the hydrostatic
the fluid is against four replenishing valves
charge relief valve
Q.
When the fluid goes to the hydrostatic pumps valves
Q and the
, the replenishing
Q on the low (charge pressure) side of the pump will open
and let fluid into the pump for replenishing, lubrication and cooling. The hydrostatic pumps
do not need the full volume of fluid flow,
so there is extra fluid. This extra fluid goes to the charge relief
valve
O .When the pressure reaches the setting of the charge relief
valve
the valve will open and let the extra fluid go to the
reservoir
©
A foot pedal controls the speed and the direction of the machine's travel. Speed is controlled by adjusting the amount of fluid that goes to
the hydrostatic motor
.and the direction is controlled by changing
the direction of fluid flow. The foot pedal is mechanically connected to a servo control cylinder
© which controls both the amount and the
direction of the fluid flow from the hydrostatic pumps
Q by
adjusting the angle of the swashplates in the hydrostatic pumps 8566681 (8-83M2.SC 39 of 252
Pimied in U.S. A
.
Resle
pumps
If the spool in the lift section of the hydraulic control valve
O is
activated, fluid will go out the respective port and to either the base end or rod end of the
cylinderÿ
0 and back to the control valve ©ÿA
opposite end of the cylinder
flow restrictor
. Return fluid comes from the
0 keeps the lift cylinder
from dropping too fast
0 also restricts the running so that the lift cylinder 0 will
when there is a heavy load. The flow restrictor
fluid when the engine is not not drop.
If the tilt section spool is activated, fluid goes out the respective port to
. Fluid then flows to either the base
the counterbalance valve
ends or rod ends of the cylinders valve to
and back to the counterbalance
ÿ from the opposite ends of the cylinders
the control valve
© from
counterbalance valve
vertical mast forward prevents
the counterbalance valve
0 keeps too
F,uid rel"rns
the cylinders
0 from
0. The
tilting the
fast when there is a heavy load and it
the vertical mast from tilting when the engine is not running.
The counterbalance valve
©
the cylinders
When the cylinders
0 does this by restricting the fluid flow to ÿ
reach the end of the stroke, the fluid
flow stops and causes hydraulic pressure
to
increase. When the
it will open and let
pressure reaches the setting of the relief valve
cooler
ÿ ,3 micron filter ©
and back to the port block
Q (Except
during cold weather operation).
When either the tilt section or lift section spool returns to neutral position, then there is more fluid available for the other section of the control valve
© . Both sections of the control valve ÿ can be used ÿis not open.
at the same time if the main relief valve
The fluid from the steering control valve port
block
which goes back to the
Q normally goes through a 40 micron filter ÿ to the
O . If the fluid is cold or if there is a sudden increase in pressure from the steering control valve , the pressure will cause the cold weather by-pass valve 0 open and put the hydrostatic pumps
to
excess fluid back to the hydraulic pump decreases.
There are
two
oil filters
The 10 micron filter element
©
located in the engine compartment.
is located on the reservoir
is located under the air cleaner. -3-1A-
40 of 252
©©
Q until the excess pressure
0 and the #3
Resle
the fluid by-pass the hydraulic circuit (internally) and go through the oil
2 HYDRAULIC SYSTEM 2-1 HYDRAULIC SYSTEM OPERATIONS 2—1.1 Description The hydraulic
system
controls the following components:
(1 )
The cylinder which lifts the vertical mast.
(2)
The cylinders which tilt the vertical mast.
(3)
The cylinder which controls the steering of the Bobcat Forklift.
The hydraulic and hydrostatic systems use the same oil reservoir, oil cooler and oil filters. Other major components of the hydraulic system are: (1)
The engine-driven vane pump which gives fluid flow to the system.
(2)
The hydraulic control valve which controls the lift and tilt cylinders.
(3)
The steering control valve which controls the articulation of the Bobcat Forklift.
(4)
The counterbalance valve which controls the tilt of the vertical mast.
2-1.2 Flow Chart NOTE:
Make reference to Chart # 6566661 for the following description of the operation of the hydraulic system.
The fluid flows from the reservoir (23) to the port block (8) which is on top of the hydraulic pump (4). The return fluid from the cold weather by-pass valve (11), by-pass valve ( 10) and the oil cooler (30) join the reservoir fluid to supply fluid to the hydraulic pump (4). "Case Drain" fluid from the hydrostatic pumps (3) flows through the 10 micron filter (25) and back to the reservoir (23).
The hydraulic pump (4) is a "vane type" pump and is driven by a shaft through the hydrostatic pumps (3). The fluid goes from the hydraulic pump (4) to the hydraulic control valve (21) and to the steering control valve (1).
The hydraulic control valve (21 ) has an adjustable relief valve (1 8). The hydraulic relief valve (18) opens when the pressure gets too high, releasing the pressure and protecting the system. The fluid that is released, returns to the oil cooler. The auxiliary section of the control valve is non-functional. When the lift and tilt section spools are in the neutral position, the fluid goes through the control valve (21 ), oil cooler (30) and the #3 element (27) and back to the port block (8). During cold weather operation the fluid will open the cooler by-pass valve (10) and the fluid will flow to the hydraulic pump inlet (4).
Resle
The steering control valve (1 1 controls the operation of the steering cylinder (2). When the steering valve (1) is actuated, the fluid goes to either the base end or the rod end of the steering cylinder (2). As the fluid goes to one end of the steering cylinder (2) the return fluid comes from the opposite end of the cylinder to the steering control vlave (1). When there is enough fluid flow to operate the steering control valve (1) the priority valve sends the excess fluid flow to the hydraulic control valve (21).
If the spool in the lift section of the hydraulic control valve (21) is activated, fluid will go out the respective port and to either the base end or rod end of the cylinder (1 3). Return fluid comes from the opposite end of the cylinder (1 3) and back to the control valve (2 1). A flow restrictor ( 1 4) keeps the lift cylinder ( 1 3) from dropping too fast when there is a heavy load. The flow restrictor (14) also restricts the fluid when the engine is not running so that the lift cylinder (13) will not drop. If the tilt section spool is activated, fluid goes out the respective port to the counterbalance valve (1 5). Fluid then flows to either the base ends or rod ends of the cylinders (12) and back to the counterbalance valve (15) from the opposite ends of the cylinders (12). Fluid returns to the control valve (21) from the counterbalance valve (15). The counterbalance valve (15) keeps the cylinders (1 2) from tilting the vertical mast forward too fast when there is a heavy load and it prevents the vertical mast from tilting when the engine is not running. The counterbalance valve (1 5) does this by restricting the fluid flow to the cylinders (12).
When the cylinders ( 1 2 ) ( 13) reach the end of the stroke, the fluid flow stops and causes hydraulic pressure to increase. When the pressure reaches the setting of the relief valve (18), it will open and let the fluid by-pass the hydraulic circuit (internally) and go through the oil cooler (30), #3 element (27) and back to the port block (8) (Except during cold weather operation). When either the tilt section or lift section spool returns to neutral position, then there is more fluid available for the other section of the control valve (21). Both sections of the control valve (21) can be used at the same time if the main relief valve (18) is not open. The fluid from the steering control valve ( 1 ) which goes back to the port block (8) normally goes through a 40 micron filter (7) to the hydrostatic pumps (3). If the fluid is cold or if there is a sudden increase in pressure from the steering control valve (1 ), the pressure will cause the cold weather by-pass valve ( 1 1 ) to open and put the excess fluid back to the hydraulic pump inlet (4) until the excess pressure decreases. There are two oil filters (25X27) located in the engine compartment. The 1 0 micron filter (25) is located on the reservoir (23) and the #3 element (27) is located under the air cleaner.
-2-1B41 of 252
2000 RTF Service Manual
2-2 TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
CAUSE
PROBLEM The hydraulic system will not operate.
1 , 2, 3, 4, 5, 6
Hydraulic action is rough,
1 , 3, 5, 7, 8, 9, 20
Slow or no hydraulic action on one section of the hydraulic control valve.
12, 13, 14, 15
The vertical mast goes up slowly at full engine RPM.
1, 3, 4, 7, 10, 14, 16, 17
The vertical mast will move or tilt with the lever in neutral position.
14, 18, 21
The vertical mast comes down slowly with the lever in the neutral position.
13, 14, 18, 19
The vertical mast will tilt forward too fast with heavy load.
21
The vertical mast will drop too fast with heavy load.
22
KEY TO CORRECT THE CAUSE
42 of 252
The fluid level is not correct. The linkage is disconnected. The hydraulic pump is not working correctly. The relief valve is not at the correct pressure. Slow engine RPM. Priority valve in vane pump is not working correctly. Incorrect viscosity fluid (See Specification for the correct fluid). Flow divider valve is not working correctly. Air in the hydraulic system. Suction leak on the inlet side of the hydraulic pump. Steering relief valve is not at the correct pressure. Cylinder seals are leaking. Port relief is not at the correct pressure. Linkage is not adjusted correctly. Spool in one section of the control valve is not working correctly. Internal leaks at the lift cylinder. Port relief valve is not working correctly. Spool centering spring is broken. External leak at the lift cylinder. Internal restriction. Counterbalance valve damaged. Flow restrictor is not working correctly. -2 — 2-
Resle
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1 1. 12. 1 3. T4. 1 5. 1 6. 1 7. 18. 1 9. 20. 21. 22.
2000 RTF Service Manual
2-3 HYDRAULIC SYSTEM INFORMATION
Mark a Line on Nut Flats of Both Nuts
When
making repairs on hydraulic keep all parts clean and remove all dirt from the area before you begin disassembly. Use caps and plugs to keep dirt out of tubelines and openings. system,
IMPORTANT
Tighten to Correct Amount from Chart
&
2 — 3.1 37° Flare Connections
Use the following procedure (1)
to tighten
the flare fittings:
Tighten the nut until it makes contact with the seat. A-1 897
Make a mark across the "flats" of both the male and female parts of the connection (Fig. 2—1). (2)
(3)
Use the chart below
to find the correct tightness
needed.
Wrench Size
Tube Size O.D.
Thread Size
Hex Flats
5/8"
5/16"
1/2" - 20
2-1/2
1 1/16"
3/8"
1/2"
- 18 3/4" - 16
2
7/8" 1"
5/8"
7/8" - 14
1-1/4"
3/4"
1-1/16" - 12
1
1-3/8"
1"
1-5/16" - 12
3/4 - 1
2"
1-1/4"
1-5/8" - 12
2-1/4"
1-1/2"
1-7/8"
9/16"
- 12
Fig. 2-1 Tightening Flare Fittings
2
1-1/2
3/4
-
-
2
1
1/2 - 3/4
If the fitting leaks after tightening, disconnect it and inspect the seat area for damage. Replace as needed.
Resle
Washer O-Ring
2 — 3.2 Straight Thread O-Ring Fitting When installing this fitting, the o-ring must be first lubricated with grease. Loosen the jam nut, turn the fitting into place and connect the tubeline, then tighten the jam nut.
Tighten the jam nut until it and the washer are tight against the surface (Fig. 2 — 2). The o-ring must be pushed into the space as shown in figure 2 2.
—
Washer 2 — 3.3 Tubelines and Hoses Replace tubelines that are bent or have become flat. There will be a restriction of fluid flow, which will result in slow hydraulic action and cause heat. Replace hoses that show signs of wear, damage or weather cracked rubber.
When installing tubelines or hoses, make sure you use two (2) wrenches when tightening them. -2-343 of 252
A-1852
Fig. 2-2
Straight Thread Seal
2000 RTF Service Manual
2-4 HYDRAULIC SYSTEM SERVICE
oC«:
Usie only recommended fluid in the hydraulic system (See Section 8 for the correct fluid
NOTE:
9
to use).
Check and add fluid, following procedure:
using
the
W)
yy
c
2 — 4.1 Checking and Adding Hydraulic Fluid
.
*y
8-6263
Fig. 2-4
The Fluid Dipstick
B-6 1 03
Put the Bobcat Forklift on a level surface.
(1)
Fig. 2-3
(2)
Lower the vertical mast and stop the engine.
(3)
Open the rear door on the Forklift.
Checking the Fluid
(5) If the fluid is below the bottom mark on the dipstick (Fig, 2 — 4, Item 1 ) add the correct amount and type of fluid until the level is at the top mark (Fig. 2 — 4, Item 2). Do not overfill. B-4023
Fig. 2-5
Removing Drain Plug
2—4.2 Replacing the Hydraulic Fluid (1 )
Clean the area around the drain plug.
(2)
Put a container under the machine and reservoir.
(3) Remove the drain plug from the reservoir (Fig. 2 — 5). Remove the fluid from the reservoir (Fig. 2 — 6).
(4)
When the reservoir is empty, install the plug and tighten.
(5)
Fill the reservoir with the correct type of fluid until the fluid level is at the 2 — 4, Item 2).
top mark on the dipstick (Fig.
-2-444 of 252
B-4022
Fig. 2-6
Removing the Fluid
2000 RTF Service Manual
Resle
(4) Remove the dipstick from the reservoir (Fig. 2 — 3, Item 1) and check the fluid level.
2 — 4.3 Replacing the Hydraulic Fluid Filters Replace the right hydraulic filter (Fig. 2 — 7) every 100 hours of machine operation or more often if necessary. Replace the left hydraulic filter #3 element (Fig. 2 — 8) when the transmission light stays "ON" for more than 5 minutes after a cold start-up.
ijpsr
To replace the hydraulic filters, use the following procedure:
The tools listed will be needed to do the following procedure:
B-6103
Fig. 2-7
1 0 Micron Filter
MEL-1 1 83 - Oil Filter Wrench
(1) Clean the area around the filter housing (Fig. 2 7 or 2 8, Item 1 ).
—
Remove the filter with a filter wrench.
(2)
—
element
(4) Install approved filter element and hand tighten only.
[/ImSS After installing a new filter, run the machine and check for leaks. (5)
2 — 4.4 Replacing the Bronze
Fig. 2-8
B-5879
Resle
(3) Lubricate the seal of the new filter element with grease.
#3 Element Filter
(40 Micron) Filter
Replace the bronze (40 micron) filter every 500 hours using the following procedure:
The tools listed will be needed to do the following procedure:
MEL-1 1 77 — 40 Micron Filter Removal Tool
(1)
Clean the area around the port block on the hydraulic pump.
(2)
Remove the tubeline and adapter from the port block. -2-5-
45 of 252
2000 RTF Service Manual
(3) Install the special tool on the filter (Fig. 2 — 9).
(4) Remove the filter, spring and sleeve together from the port block (Fig. 2-10).
(5) Remove the special tool from the filter (Fig. 2—11).
NOTE:
DO NOT remove the sleeve before removing the bronze filter. Particles trapped by the filter may drop into the port block and enter the system. Always check the port block bore for debris and clean the bore.
(6) Put the sleeve on the filter and lubricate the o-ring oil. Install the filter, sleeve spring into the port block
Fig. 2-9
Installing Too!
new with and (Fig.
2-12).
Install the plug and tighten.
Resle
(7)
2 — 4.5 Replacing the Neutral By-Pass Valve Replace the neutral by-pass valve, using the following procedure:
(1)
B-6008
Fig. 2-10
Removing the Filter
Clean the area around the
port block on the hydraulic pump.
Fig. 2-11
Removing the Tool
(2) The cooler by-pass valve is located on the right side of the port block (Fig. 2—13, Item 1 ).
(3) Remove the fitting, spring and poppet.
(4) Clean and inspect the parts for wear or damage.
Install the poppet, spring and tighten the fitting.
46 of 252
B-5640
B-6009
(5)
Fig. 2-12
Installing the Filter
-2 — 6-
Fig. 2-13
Port Block
2000 RTF Service Manual
2 — 4.6 Replacing the Cold Weather By-Pass Valve
\\
\
Replace the cold weather by-pass valve, using the following procedure: (1 )
Clean the area around the port block on the hydraulic pump.
(2)
The cold weather by-pass valve is located on the right front of the port block (Fig. 2 — 13, Item 2). (3)
\! •it \1
Remove the fitting, spring and the poppet.
(4) Clean and inspect the parts for wear or damage. Replace the parts as needed.
(5)
1 1
//
1 i\
Install the poppet, spring and tighten the fitting.
//
2-5 OIL RESERVOIR
/ 8-5641
Fig. 2-14
2 — 5.1 Removing the Oil Reservoir
Removing Suction Hose
To Remove the oil reservoir, use the following procedure: (1 )
Lower the vertical mast and stop the engine.
Lift the Bobcat Forklift and put blocks under it (See Paragraph 1 —2, Page 1 - 1 ).
(2)
(3)
Remove the fluid from the reservoir (See Paragraph 2 — 4.2).
Remove the suction hose from the reservoir (Fig. 2 — 14) and from the port block.
(5)
Remove the tubelines from the oil filter housing (Fig. 2—15).
(6)
Disconnect the wire from the temperature switch.
(7)
Remove the top bolts (Fig. 2—16) and the bottom bolts from the reservoir
Resle
(4)
(Fig. 2-17). (8)
Remove the reservoir from the machine.
2 — 5.2 Installing the Oil Reservoir ( 1 ) Install the suction hose in the machine and connect it at the port block and the reservoir (Fig. 2—14).
5642
Fig. 2
Install the reservoir in the machine.
(2)
— 15
Filter Hose
(2) Install the bottom and top bolts and tighten (Figs. 2—16 & 2-17). (4) Connect the tubeline at the filter housing (Fig. 2—15). (5) Connect the wire to the temperature switch (Fig. 2—17, Item 1 ).
(6) Fill the reservoir with the correct fluid (See Paragraph 2-4.2).
47 of 252
B-5644
B-5643
Fig. 2 — 16 Reservoir Bolts (Topi
-2-7-
Fig. 2-17
Reservoir Bolts (Bottom)
2000 RTF Service Manual
2-6 HYDRAULIC CONTROL VALVE
2 — 6.1 Description of the Control Valve
a
MAIN RELIEF
VALVE
The hydraulic control valve is an open center, closed port valve which controls the Bobcat Forklift hydraulics.
INLET
OUTLET
control valve is actuated by mechanical linkages to the operator control lever.
The
u
TT 8-57 62
Fig. 2-18
Control Valve
Resle
The control valve has the following (Fig. 2—18):
1
2
3
E
F
G
Port
End Cap
Machined
Port Not Machined
Lift Spool
Plugged Port
Plugged Port
Auxiliary Spool
Port Not Machined
Port Not Machined
A
B
C
D
Rod End Port (Tilt)
Base End Port (Tilt)
Tilt Load Check
Tilt Spool
Rod End Port (Lift)
Base End Port (Lift)
Lift Load Check
Plugged Port (Auxiliary)
Plugged Port (Auxiliary)
Auxiliary Load Check
48 of 252
-2
— 8-
Not
(Tilt)
End Cap (Lift)
End Cap (Auxiliary)
2000 RTF Service Manual
1
2 — 6.2 Removing the Hydraulic Control Valve
//
i
1
To remove the hydraulic control valve use the following procedure:
(1 )
-fij 1 Ml 14 \
ÿ
fc
Lower the vertical mast and stop the engine.
ÿ
[
¥
J
1 (2) Actuate the hydraulic control levers to release all the hydraulic pressure in the system.
Fig. 2—-19 (3)
B-5646
ÿ
Control Valve Bolts
Install the frame lock.
.'
,
1
"A"'" J' K.1
,
(4) Remove the floormat and the floorpanels (See Paragraph 5 — 3.1, Page 5-1).
(5) Remove the covers (both inside and outside) over the control linkage and the control valve.
8-5647
Disconnect the mechanical linkages from the control valve.
(7) Loosen the bolts which remove the bolt at this time.
NOTE:
(8)
mount the
Fig. 2
— 20
Port Block Tee
control valve (Fig. 2—19), Do not
Mark the hoses and tubelines so they are installed in the correct locations when the control valve is replaced in the machine.
Resle
(6)
3
Disconnect the tubelines and hoses from the control valve. Plug the ports. B-5935
Fig. 2-21
Pivoting Control Valve
(9)
Remove the tubeline that is connected to the tee fitting at the port block (Fig. 2 — 20, Item 1 ).
( 1 0) Pivot the shelf down and remove the hoses and tubelines at the front of the control valve (Fig. 2 — 21).
(11) Remove the
four (4) bolts which hold the shelf and control valve in the machine (Fig. 2 — 21, Item 1).
( 1 2) Remove the control valve from the machine and remove the mounting shelf from the control valve.
-2-949 of 252
2000 RTF Service Manual
2 — 6.3 Disassembly of the Control Valve
IMPORTANT
When making repairs on the hydraulic control valve, keep all parts clean and remove all the dirt from the control valve. Use caps and plugs to keep dirt out of the tubelines or ports.
Fig. 2
— 22
Load Check
To disassemble the hydraulic control valve use the following procedure:
Mark each section and spool of the control valve so that each can be returned to its original bore during assembly.
MAIN
(1)
VALVE
INLET
Put the control valve on a work bench and install bolts through the valve and bench for easier disassembly. (2)
OUTLET
Remove the load check valves — 22) from the three (3) center ports (Fig. 2 — 23, Items C1 , C2 and C3) in the top section of the control valve.
Resle
(3)
(Fig. 2
u :5762
Remove the plug (Fig. 2 — 24, Item 1) from the end port (Fig. 2 — 23, Item E2) in the top section of the control valve. (4)
Fig. 2-23
Control Valve
(5) Remove the o-rings and back¬ up washers from the plugs.
(6) Loosen the bolts which fasten the rubber boots to the lower section of the control valve with an alien wrench.
B-5875
Fig. 2-24
Port Plug
-2-1050 of 252
2000 RTF Service Manual
(7) Remove the bolts (Fig. 2 — 25, Item 1 ), rubber boots (Item 2), boot retainer (Item 3), filter (Item 4) and o-ring back-up (Item 5) from each of the three (3) spools (Fig. 2 — 23, Items D1, D2 and D3).
(8) Using a screwdriver, remove the o-ring spool seal from each of the three (3) spool bores (Fig. 2 — 25, Item 6).
(9) Loosen the main relief valve from the port (Fig. 2 — 23) on the control valve.
B-5804
(10) Remove the main relief valve (Fig. 2 — 26).
Fig. 2-25
Spool Assembly
(11) Remove the plug (Fig. 2— 24, Item 2) from the port (Fig. 2 23, Item F2). Remove the o-rings and
—
back-up washers from the plugs.
(12) Remove the bolts which fasten the end cap over the tilt spool to the control valve (Fig. 2-27).
(1 3) Remove the end cap from the tilt spool.
B-5832
B-5880
Fig. 2-26
Fig. 2 — 27
Main Relief Valve
End Cap
(1 4) Using an alien wrench, loosen
AWARNING
Resle
the bolt which holds the centering spring to the tilt spool (Fig. 2 — 28) while holding the spool on the opposite end.
Loosen the bolt from the spool carefully. There is spring tension.
—
(1 5) Remove the bolt (Fig. 2 29, Item 1). Remove the adapter (Item 2), the collar (Item 3), the spring (Item 4) and the washer (Item 5) from the spool.
B-5939
Fig. 2-28
Removing Centering Spring
Q
(16) Remove the back-up washer
(Fig. 2
— 29, Item 6) and the o-ring
(Item 7).
(17) Remove the spool from the control valve (Fig. 2 — 30) thru the
rear.
(18) Repeat steps 13 thru 18 for the lift section and for the auxiliary section.
Fig. 2-29
Spool Assembly
-2-1151 of 252
B-5944
B-5942
Fig. 2-30
Removing Spool
2000 RTF Service Manual
2 — 6.4 Inspection of the Control Valve (1) Check the spools for scratches or wear. If scored or pitted, replace the spools and valve as an assembly.
(2) Check that the spools are not loose in their bores. If they are loose there may be damage or wear to the control valve block.
(3)
Check that the centering springs are not broken.
(4)
Check that the load check seats are not worn.
(5)
Check that the load check poppets are not worn.
(6)
Check that the rubber spool boots, boot retainers and filters are not worn.
(7)
Replace any parts that are worn or broken.
2 — 6.5 Reassembly of the Control Valve (1)
Make sure all o-ring grooves are clean.
(3)
Install the spool in the tilt section bore (Fig. 2 — 30).
(4)
Install two (2) o-rings on the tilt section spool, one on each end.
Resle
(2) Lubricate all o-rings with grease. Use new o-rings in the control valve when reassembling.
—
(5) Install the back-up washer (Fig. 2 29, Item 6) and centering components (Items 2, 3, 4 and 5) on the spool and install the bolt (Item 1).
(6)
Replace the end cap.
(7)
Repeat steps 3 thru 6 for each of the other two (2) spools.
(8) Replace the plug in the port (Fig. 2 — 23, Item F2) with o-rings and back-up washers.
(9) Replace the main relief valve (with o-rings and back-up washers) in the port (Fig. 2 26).
—
( 10) Make sure the o-ring is in the correct position on each spool and replace the filter (Fig. 2 — 25, Item 4), Boot retainer (Item 3), rubber boots (Item 2), and bolts (Item 1) on the three (3) spools.
(11) Replace the plug (with o-rings and back-up washers) in the port (Fig. 2 — 23, Item E2) in the control valve.
(12) Replace the load checks (with o-rings) in the three (3) center ports (Fig. 2 — 23, Items C1 , C2 and C3) of the control valve.
-2-1252 of 252
2000 RTF Service Manual
2 — 6.6 Installing the Control Valve To install the hydraulic control valve in the Bobcat Forklift use the following procedure: (1 )
Put the control valve on the shelf. Install the bolts and hand tighten only.
(2) Install the control valve and shelf assembly into the machine. Install the four (4) bolts.
(3)
Connect the hoses to the control valve.
(4)
Pivot the shelf and control valve into position and connect the tubelines.
(5)
Connect the tubeline at the tee fitting at the
(6)
Connect the mechanical linkage to the control valve.
(7)
Tighten the four bolts which mount the control valve to the shelf.
(8)
Install the cover over the linkage.
port block.
(9) Install the floorpanels and the floormat (See Paragraph 5 5-1).
Start the engine and operate the hydraulic controls.
(11)
Check for leaks.
Page
Resle
(10)
— 3.2,
(12) Stop the engine. Check the fluid reservoir and add the correct fluid as needed.
2-7 HYDRAULIC MAIN RELIEF VALVE
2 — 7.1 Checking the Hydraulic Main Relief Valve The tools listed will be needed to do the following procedure: MEL-10003 — Flow Tester MEL- 10006 - Test Kit ( 1)
Lower the vertical mast and stop the engine.
(2)
Activate the control to release the hydraulic pressure.
Lift and block the Bobcat Forklift (See Section 1—2, Page 1 correct procedure).
(3)
-2—1353 of 252
— 1 for
the
2000 RTF Service Manual
(4) Disconnect the hose from the base end tilt circuit port on the control valve (Fig. 2 — 31, Item
Fl
A1).
Disconnect the hose from the rod end tilt circuit port on the control valve (Fig. 2 — 31, Item B1 ). (5)
(6)
F2
MAIN RELIEF VALVE .
Plug the two (2) hoses.
Using the correct adapters from the test kit, connect the hose from the outlet of the flow tester to the bottom port of the tilt section (Fig. 2-31 , Item A1 ). (7)
INLET
Oi- OUTLET
(8) Connect the hose from the inlet of the flow tester to the top port of the tilt section (Fig. 2 — 31 , Item B1 )•
DI
D2
D3 8-5762
IMPORTANT
Fig. 2-31
Hydraulic Control Valve
Resle
The restriction control on the tester must be fully open before you start the engine.
(9) Start the engine and run at idle speed. Engage the control lever and move the spool (in or out) to make sure the flow through the flow tester is in the correct direction. Increase the engine speed to 2600 RPM.
NOTE:
There will be a small amount of flow at idle speed because the priority valve in the hydraulic pump sends fluid to the steering motor until there is enough fluid flow for both the steering and the hydraulics.
(1 0) The free
flow GPM through the flow meter must be 1 4.5 GPM.
(11) Turn the restriction control of the flow tester in the "increase" direction. Watch the buildup of pressure on the pressure gauge. (12) Increase the restriction until the flow gauge starts to move down scale. The flow is decreasing because the relief valve is opening.
(1 3) Note the pressure on the pressure gauge. The relief valve must operate at about 2600 PSI (1 861 7 kPa) when there is 9 GPM flow. (14) If the pressure or flow can not be reached, the problem could be the relief valve or the hydraulic pump. Go to paragraph 2 — 8.1 to find the problem.
-2-1454 of 252
2000 RTF Service Manual
2
— 7.2 Replacing the Hydraulic Main Relief Valve ( 1)
Stop the engine.
(2)
Activate the hydraulic controls to release the hydraulic pressure in the
system.
(3)
Remove the covers over the control valve.
(4)
Clean the area around the relief valve.
(5)
Remove the relief valve, o-rings and back-up washers from the control
valve (Fig. 2 — 32). (6)
B-5876
Fig. 2-32
Clean and inspect all the parts. Replace the worn or damaged
Main Relief Valve
parts as
needed. (7) Install and check the hydraulic relief valve operating pressure (See Paragraph 2 — 7.1). If the pressure is still not correct after cleaning, replace or adjust the relief valve.
NOTE:
To set the operating pressure of the main relief valve, remove the end cap and turn the adjustment screw in or out using an alien wrench. Turn the adjustment screw in (clockwise) to increase the PSI. Turn the adjustment screw out (counterclockwise) to decrease the PSI. Turn the adjustment screw a small amount and check the hydraulic relief valve (See Paragraph 2 — 7.1). Repeat turning the adjustment screw a small amount and checking the pressure until it is correct.
2-8 HYDRAULIC PUMP
Resle
The hydraulic pump is an engine driven vane pump which provides hydraulic fluid, under pressure, for lift and tilt functions and the steering function.
2 — 8.1 Checking the Hydraulic Pump Pressure The tools listed will be needed to do the following procedure:
MEL-10003 — Flow Tester MEL-1 0006 - Test Kit (1 ) Lower the vertical mast and stop the engine. Operate the hydraulic control to release the hydraulic pressure in the system.
(2) Lift and block the machine (See Paragraph 1—2, Page 1—1 for the correct procedure).
(3) Remove the floormat and the floorpanel (See Paragraph 5 — 3.1, Page 5-1).
(4)
Clean the area around the hydraulic pump.
(5) Remove the hose connected from the hydraulic pump to the hydraulic control valve.
(6) Connect the inlet hose of the flow tester to the outlet of the hydraulic pump.
-2-1555 of 252
2000 RTF Service Manual
(7) Connect the outlet hose of the flow tester to the inlet port of the hydraulic control valve. Open the restriction control on the flow tester all the way.
IMPORTANT
Be sure to open the restriction control on the flow tester all the way. Failure to do so may cause damage to the ring in the hydraulic pump.
B-5655
Fig. 2-33
IMPORTANT
Removing Bracket Bolts
The tester is connected ahead of the main relief valve. When adjusting the restriction control, be sure that the pressure reading does not exceed 2500 PSI (17463 kPa).
(8) Start the engine and run it at idle speed. There must be no movement (or very little movement) of the flow tester gauge. The priority valve in the hydraulic pump is directing most (or all) of the fluid to the steering control valve.
(9)
Increase the engine speed to 2600 RPM. B-5656
(10) Watch the free flow GPM on the tester gauge, it must be approximately
14.5 GPM.
pjg 2
— 34
Removing the Bolts
(11) Watch the pressure gauge as you slowly increase the restriction control to 2500 PSI (18617 kPa). DO NOT exceed 2500 PSI (18617 kPa).
2
Resle
(12) Note the flow GPM with a restriction of 2500 PSI (18617 kPa) and the hydraulic pump is good if the flow is 85% of the free flow GPM.
— 8.2 Removing the Hydraulic Pump ( 1 ) Lower the vertical mast and stop the engine. Operate the hydraulic controls to release the hydraulic pressure in the system. B-5657
(2)
Remove the floormat and floorpanel (See Paragraph 5 — 3.1 , Page 5— 1 ).
(3)
Clean the area around the hydraulic pump.
Fig. 2-35
Removing the Pump
(4) Mark and disconnect all the hoses and tubelines from the hydraulic pump and the port block. Put plugs in all the ports, hoses and tubelines. (5) Remove the bolts that fasten the brackets to both sides of the hydraulic pump (Fig. 2 33). Loosen, but do not remove the bolts at the other end of the brackets so that the brackets can be moved out of the way.
—
(6)
Remove the two bolts that fasten the hydraulic pump to the hydrostatic
pump (Fig. 2
— 34).
(7) Move the hydraulic pump and port block forward, under the oscillating link and remove the hydraulic pump from the machine (Fig. 2 — 35).
56 of 252
-2-16-
2000 RTF Service Manual
Fig. 2-36
2
Hydraulic Pump Assembly
— 8.3 Disassembly The Hydraulic Pump (Fig. 2 — 36).
While disassembling the pump, mark the parts for correct reassembly.
Resle
( 1) Remove the port block from the hydraulic pump. Remove the 4 bolts (Item 1) which fasten the cover (Item 2) and remove the cover from the pump.
(2) Remove the spring (Item 3), o-ring (Item 4), pressure plate (Item 5) and locating pins (Item 6) from the pump. (3) Remove the ring (Item 7), rotor (Item 8) and vanes (Item 9) from the body (Item 10) as an assembly. Hold the rotor and vanes to prevent them from coming apart. Note the direction of the arrow on the ring (Item 7).
(4) Remove the o-rings (Item 1 1 ), snap ring (Item 1 2), coupler (Item 1 3) and shaft (Item 14) from the body. (5) Remove the plugs (Item 15) and o-rings (Item 16) from each end of the cover (Item 2). (6)
Remove the spring (item 17) and priority valve spool (Item 18).
(7)
Remove the pipe plug (Item 19) and o-ring (Item 20).
(8) Remove the shims (Item 21 ), spring guide (Item 22), spring (Item 23) and poppet (Item 24) from the relief valve port. (9) Do not remove the seat (Item 25) unless (Item 25) show wear or damage.
the poppet (Item 24) and seat
-2-1757 of 252
2000 RTF Service Manual
2 — 8.4 Inspection of the Hydraulic Pump (Fig. 2 — 36) NOTE:
All parts must be cleaned and kept clean during checking and assembly. Clean all the parts with solvent and use filter compressed air for cleaning. This is very important because of the tight clearance of the parts.
(1 )
Check all the parts for excessive wear.
(2)
Check the ring (Item 7) for scratches, cracks and wear.
(3) Check the cover bore (Item 2) for burrs and scratches. Check the spool (Item 1 8) for burrs, chips and wear. Spool must move freely in the bore.
(4)
Check the vanes (Item 9) and rotor (Item 8) clearance. Vanes must slide
freely in and out of the rotor.
2 — 8.5 Assembling the Hydraulic Pump (Fig. 2 — 36)
During assembly of the hydraulic pump, use grease to hold the seals in place. Lubricate all the parts with fluid to provide initial lubrication.
NOTE:
Resle
(1 ) Install the shaft (Item 1 4), coupler (Item 1 3) and snap ring (Item 1 2) into the body (Item 1 0).
(2)
Install the body o-ring (Item 1 1).
(3)
Install the locating pins (Item 6) into the body.
o Install the ring (Item 7) with the arrow pointing in the direction of pump rotation. (4)
(5)
°
O
Install the rotor (Item 8) into the ring.
Round Install the canes (Item 9) into the rotor with the radius edges of the vanes (Fig. 2 — 37) out toward the ring (Item 7). (6)
(7) Install the pressure plate (Item 5) over the locating pins (Item 6) and the rotor (Item 8). The pressure plate can be assembled on the pins in either
Fig. 2-37
direction.
58 of 252
A- 1 865
-2-18-
Vane Location
2000 RTF Service Manual
(8) Install the o-ring (Item 4) over the pressure plate (Item 5) and install the spring (Item 3) on the pressure plate.
(9) Install the cover (Item 2), check the markings so that the pressure port is in the correct direction.
(10) Install the 4 bolts (Item 1) into the cover and tighten to 85 (115- 129 Nm) torque.
-
95 ft. -lbs.
(1 1) Install the relief valve poppet (Item 24).
(1 2) Install the spring (Item 23), spring guide (Item 22) and shims (Item 21 ).
NOTE:
The shims (Item 21) are used to set the relief valve opening pressure. The addition of shims increases the pressure. Set the relief valve opening pressure during the test after pump assembly.
(1 3) Install a new o-ring (Item 20) and tighten the pipe plug (Item 1 9).
(1 4) Install the priority valve spool (Item 1 8) and spring (Item 1 7).
(1 5) Install the new o-rings (Item 1 6) and tighten the plugs (Item 1 5). I-5656
(1 6) Install the port block on the hydraulic pump.
Fig. 3 — 38
Installing Pump Bolts
Fig. 3-39
Installing the Bracket
2 — 8.6 Installing the Hydraulic Pump
Resle
(1) Install the port block and hydraulic pump in the machine under the oscillating link and make alignment of the mounting holes.
(2) Install the two bolts that fasten the hydraulic pump to the hydrostatic pump and tighten (Fig. 2 — 38).
(3) Put the brackets in the correct location and install the bolts and tighten all the bolts (Fig. 2 — 39).
B-5655
Connect all the hoses and tubelines to the hydraulic pump and the port block. (4)
2 — 8.7 Checking Steering Relief Pressure The tools listed will be needed to do the following procedure:
MEL-10003 — Flow Tester MEL-1 0006 - Test Kit ( 1)
Lift and block the machine (See Paragraph 1—2, Page 1—1 for the correct
procedure). B-5739
(2)
Remove the bottom tubeline from the hydraulic pump (Fig. 2 — 40).
59 of 252
-2-19-
Fig. 2-40
Hydraulic Pump Tubeline
2000 RTF Service Manual
(3) Connect the flow tester from the outlet of the pump to the inlet of the tester (Fig. 2 — 41 , Items 1 ). Connect the other hose from the tester to the line that was removed (Fig. 2 — 41, Items 2). Make sure the restriction control is in the "OFF" (open) position.
(4) Start the engine and run it at 2600 RPM.
B-5738 B-5740 B-5656
Turn the restriction control to read the relief pressure of 2285 PSI (1 5755 kPa). (5)
Fig. 2-41 Connecting Flow Tester (6) If the pressure is not correct, add or remove shims to increase the pressure or to decrease the pressure at the steering relief valve (See Fig. 2 36, Item 21).
—
2-9 COUNTERBALANCE VALVE The counterbalance valve (Fig. 2 — 42, Item 1) restricts fluid flow to the tilt cylinders. If the counterbalance valve is working correctly the vertical mast will NOT tilt forward too quickly when there is a heavy load on the pallet forks.
Resle
The counterbalance valve will also keep the vertical mast from tilting when the control lever is moved or bumped by accident when the engine is not running.
If the load tips forward too quickly when the vertical mast is tilted forward or if the vertical mast can be tilted when the engine is not running, replace the counterbalance valve. If the problem goes away, the counterbalance valve that was replaced is damaged.
2-10 HYDRAULIC CYLINDERS
2—10.1 Checking the Lift Cylinder Seals Leakage within the cylinder can cause loss of hydraulic power.
If the vertical mast will not hold when moved up or if the lift is slow at fast engine RPM and there are no outside leaks in the system, the port relief valve may be leaking or the cylinder piston seal or control valve spools can have internal leakage.
-2-2060 of 252
2000 RTF Service Manual
2 — 10.2 Checking the Tilt Cylinder Seals Leakage within the cylinders can cause loss of hydraulic power.
If the vertical mast will not hold when tilted system, the tilt cylinder piston seals or
back and there are no outside leaks in the control valve spools can have internal
leakage.
Check the tilt cylinder seals, using the following procedure: ( 1)
Lower the vertical mast and tilt it fully back. Use a block to hold the vertical
B-5888
mast in this position.
Fig. 2
— 42
Checking Tilt Cylinder Seals
(2) Stop the engine and activate the hydraulic control to release pressure in the hydraulic system.
(3)
Lift and block the machine (See Paragraph 1 —2, Page 1—1 for the correct
procedure).
(4) Disconnect the two (2) hoses (Fig. 2 — 42, Item 2) from the rod ends of the tilt cylinders and plug the hose ends.
(5) Disconnect the two (2) hoses (Fig. 2 — 42, Item 3) from the base ends of the tilt cylinders and plug the hose ends.
(6) Disconnect the hose (Fig. 2 — 42, Item 4) coming from the rod end port of the tilt section of the control valve to the port on the front side of the counterbalance valve (Item 1 ). Disconnect it at the port on the counterbalance valve and plug the port.
Connect the hose to the rod end of one tilt cylinder.
Resle
(7)
(8) Start the engine and run at low RPM. Move the hydraulic control to the left. Look for fluid leakage at the open cylinder port. Move the throttle to fast RPM and check the open cylinder port again.
(9) The cylinder piston seals are good if only a small amount of fluid comes from the open cylinder port.
(1 0) Disconnect the hose from the rod end of the tilt cylinder and connect it to the rod end of the other tilt cylinder.
(11) Repeat steps 8 and 9.
(1 2) Disconnect the hose from the rod end of the tilt cylinder and connect it to the counterbalance valve.
(13) Connect the four (4) hoses to the tilt cylinders correctly (Fig. 2 2 and 3).
(14)
— 42, Items
Check the rod end of the cylinder for leakage past the rod end seals. -2-21-
61 of 252
2000 RTF Service Manual
2—10.3 Checking the Steering Cylinder Seals If the movement of the steering cylinder is slow at fast engine RPM, the cylinder piston seals or steering control valve spool may have internal leakage.
Check the steering cylinder seal, using the following procedure: (1 )
Put the machine on a level surface and lower the vertical mast.
(2)
Turn the machine to the left as far as it will go. Stop the engine.
(3)
Remove the floormat and floorpanels (See Pargraph 5 — 3.1, Page 5—1).
(4) Disconnect the hose at the base end of the steering cylinder. Put a plug in the hose end.
NOTE:
DO NOT move the steering wheel until the engine is started again after the hose is disconnected.
(5) Start the engine and run at low RPM. Turn the steering wheel to the left. Look for fluid leakage at the open port of the cylinder. Move the throttle to fast RPM and check for fluid leakage at the open port of the cylinder.
AWARNING
Move the steering wheel ONLY to the left after the engine is started. BE SURE the procedure is done correctly. Failure to obey warnings will cause injury or
Resle
death.
(6) The cylinder piston seal is good if only a small amount of fluid comes from the open port.
(7)
Install the hose.
(8)
Check the rod end of the cylinder for leakage past the rod end seal.
2—10.4 Removing the Lift Cylinder (1)
Install the steering frame lock and engage the park brake.
(2)
Lower the vertical mast.
(3)
Tilt the vertical mast forward until the carriage chains are loose (Fig. 43).
Stop the engine. Activate the control lever to release pressure in the lift section of the control valve.
B-5856
(4)
-2-2262 of 252
Fig. 2-43
Vertical Mast Carriage Chains
2000 RTF Service Manual
(5) Remove the two (2) mounting bolts at the top of the lift cylinder (Fig. 2 — 44, Item 1 ).
NOTE:
The carriage chain must be lifted to remove the mounting bolts.
O
(6) Put a jack under the upright frame (Fig. 2 — 43, Item 1) and raise the inner rail of the vertical mast about six (6) inches.
B-5858
Fig. 2-44
Top Mounting Bolts
//
IMPORTANT
Fig. 2
When making repairs on hydraulic system, keep all parts clean and remove all dirt from the area before you begin disassembly. Use caps and plugs to keep dirt out of tubelines and openings.
— 45
B-5859
Lift Cylinder Rod End Hose
B-5877 Plastic Strap Holding Hose
(7) Disconnect the hose connected to the top (rod end) of the lift cylinder (Fig. 2 — 45). Remove the plastic straps holding the hose to the lift cylinder (Fig. 2 — 46) and pull the hose away from the cylinder.
B-5883
Fig. 2-48
Disconnect the hose connected to the bottom (base end) of the lift cylinder at the connection near the mounting frame (Fig. 2 47, Item 1).
Resle
Fig. 2-46
Attaching Chain Hoist
(8)
—
AWARNING (9)
!B-5878
Fig. 2-47
Base End Hose
Release pressure before disconnecting hydraulic cylinders and hoses. Fluid under pressure can cause serious injury.
Fasten a chain hoist to the lift cylinder (Fig. 2 — 48).
( 10) Remove the bolt connecting the bracket at the bottom of the lift cylinder to the mounting frame (Fig. 2 — 49, Item 1).
-2-2363 of 252
Fig. 2-49
Mounting Bracket
2000 RTF Service Manual
(11) Lift the lift cylinder up with the chain hoist until the supporting bracket at the top of the lift cylinder (Fig. 2 — 50, Item 1 ) comes away from the bracket on the outer rail of the upright. (1 2) Lift the cylinder away from the machine.
2—10.5 Inspecting the Lift Cylinder (1) Inspect the cylinder rod for debris, chemical residue, paint, nicks, etc. on the polished surface.
(2)
Check for leakage around the rod seal.
(3)
Check for signs of leakage at the flow restrictor (Fig. 49, Item 2).
(4)
Do a lift cylinder drift test (See Paragraph 5A — 4, Page 5A — 3). I-5885
Fig. 2-50
2 — 10.6 Installing the Lift Cylinder
Support Bracket
(1) Raise the lift cylinder with a chain hoist and move it into position on the vertical mast.
Lower the cylinder so the supporting bracket near the top of the cylinder (Fig. 2 — 50, Item 1 ) moves into position on the bracket on the outer rail of the vertical mast. (2)
(3) Install the bolt and connect the bottom of the lift cylinder to the mounting frame (Fig. 2 — 49). (4) Lower the jack under the vertical mast until the inner rail rests on the lift cylinder (Fig. 2 — 43).
— 44) and connect the lift cylinder to the top Resle
(5) Install the two (2) bolts (Fig. 2 of the upright frame.
(6) Connect the hydraulic hoses to the lift cylinder. Install new plastic straps to hold the hose which goes to the top of the cylinder. (7)
Start the engine and operate the hydraulic control lever. Check for leaks.
(8)
Check the level of fluid in the reservoir.
2—10.7 Removing the Tilt Cylinders NOTE:
Do not remove both tilt cylinders at the same time. One cylinder will stabilize the vertical mast while the other is removed.
(1)
Install the steering frame lock and engage the park brake.
(2)
Raise the vertical mast about four (4) feet from the ground.
(3)
Tilt the vertical mast fully forward.
(4) Lower the vertical mast until the pallet forks are touching the ground (Fig. 2-51).
(5) Stop the engine. Activate the control lever to release pressure in the hydraulic system.
NOTE:
Mark the hydraulic hoses connected to the tilt cylinders so that when the cylinders are replaced they are connected correctly.
64 of 252
-2-24-
B-5887
Fig. 2-51 Vertical Mast
in Position
2000 RTF Service Manual
IMPORTANT When making repairs on hydraulic systems, keep all parts clean and remove all dirt from the area before you begin disassembly. Use caps and plugs to keep dirt out of tubelines and openings.
(6) Disconnect the hose coming from the rod end of the tilt cylinder at the counterbalance valve (Fig. 2-52, Item 1).
Fig. 2 Disconnect the hose at the base end of the cylinder (Fig. 2 — 52, Item 2)
Tilt Cylinder Hoses
(7)
AWARNING (8)
Be careful when disconnecting hoses from hydraulic cylinders. Fluid under pressure can cause serious injury.
Remove two bolts from the rod end of the tilt cylinder (Fig. 2 — 53, Item 1 ).
(9) Use a punch and hammer and remove the pivot pin connecting the rod end of the cylinder tb the vertical mast (Fig. 2 — 54).
(11) Remove the
Resle
( 1 0) Remove the nut and bolt connecting the base end of the tilt cylinder to the front main frame (Fig. 2 — 52, Item 3).
tilt cylinder from the machine.
2—10.8 Installing the Tilt Cylinders
NOTE:
If a new tilt cylinder is installed, install a 45° grease zerk on the base end.
(1 ) Put the tilt cylinder in position on the machine. Connect the base end of the tilt cylinder to the front main frame with the bolt and nut (Fig. 2 — 52, Item 3). Be sure the spacers are in correct position. Tighten to 900 to 1000 ft. -lbs. ( 1 200 to 1356 Nm) torque.
(2) Extend the rod of the cylinder to make alignment of the rod end
pivot pin holes with the bracket on the vertical mast (Fig. 2 — 52, Item 4).
(3) Install the rod end pivot pin and two bolts (Fig. 2 — 53). (4) Connect the hydraulic hoses and tighten. (5) Start the engine and operate the hydraulic control lever. Check for leaks and check the level of fluid in the reservoir.
B-5868
Fig. 2 - 53
Removing Nut and Pin Lock
-2-2565 of 252
B-5869
Fig. 2
— 54
Pivot Pin
2000 RTF Service Manual
2—10.9 Removing the Steering Cylinder Lift and block the machine. Install the steering frame lock (See Paragraph 1—2, Page 1—1 for the correct procedure).
(1)
(2) Lower the vertical mast and stop the engine. to release the hydraulic pressure in the system.
Activate the hydraulic control
Remove the floormat and floorpanels from the machine (See Paragraph 5-3.1, Page 5-1).
(3)
(4)
Disconnect the hoses from the cylinder.
(5)
Remove the bolt and nut from the rod end of the steering cylinder.
(6)
Remove the bolt and nut at the base end of the cylinder.
NOTE:
(7)
NOTE:
Make sure not to lose the two special washers on each end of the steering cylinder. Remove the steering cylinder from the machine. To disassemble and repair the steering cylinder (See Paragraph 2—10.1 1 for the correct procedure).
2—10.10 installing the Steering Cylinder
The tools listed will be needed to do the following procedure: MEL-10043 MEL-10390
— Torque Wrench — Torque Multiplier
(1) Put the steering cylinder in the machine in the correct location. Make alignment of the holes at the base end of the cylinder. (2) Install the base end bolts, special washers and nut (nut goes to the bottom).
The special washers must have the tapered sides next to the cylinder eye on each side.
Resle
NOTE:
(3) Extend the cylinder rod to make alignment of the holes at the rod end of the cylinder. (4)
Install the pin, special keeper plate and bolt.
(5) Tighten the nuts and bolts at each end of the steering cylinder to 900 -1000 ft. -lbs. (1220 - 1356 Nm) torque. (6)
Connect the two hydraulic hoses to the cylinder and tighten.
(7) Install the floorpanels and the floormat (See Paragraph 5 5-1).
— 3.2,
Page
(8) Remove the steering frame lock and the jackstands from under the machine.
2—10.11 Disassembly of the Hydraulic Cylinder
NOTE: The following procedure can be used for the tilt and steering cylinders. The tools listed will be for either of the tilt or steering cylinders. The tools listed will be needed to do the following procedure: MEL-1075 — Spanner Wrench MEL-1 074 - O-Ring Seal Hook NOTE:
The photos in the figures may not be exactly the same as the cylinder you are working on, but the procedure will work.
-2-2666 of 252
2000 RTF Service Manual
(1)
Put the base end of
the
cylinder in a drain pan and move the rod in and out to remove the fluid from the cylinder.
(2) Put the base end cylinder in a vise.
of
the
B-3665
-5025
Remove the end cap from the cylinder with the special tool (Fig. (3)
Fig. 2-55
Fig. 2-56
Removing End Cap
Removing Piston & Rod
2-55).
(4) Remove the rod with the end cap and piston from the cylinder (Fig. 2-56).
(5)
Remove the cylinder housing
from the vise. B-3683
-3670
Fig. 2-57
Fig. 2-58
Removing Nut
(6) Put the rod end in the vise and remove the nut (Fig. 2 — 57).
Removing the Piston
(7) Remove the piston from the rod (Fig. 2-58).
1
Resle
(:,/ "~vf/
VrVCi 1 \X) -1
Remove the end cap from the rod (Fig. 2 — 59).
(8)
B-4678
B-3685
Fig. 2-59
Fig. 2
Removing the End Cap
— 60
Removing O-Ring
(9) Remove the o-ring and back¬ up washer from the end cap (Fig. 2-60).
(10) Remove the wiper seal from the end cap (Fig. 2 — 61).
(11) Remove 2-62).
Fig. 2-61 Removing Wiper Seal
-2-2767 of 252
B-4671
B-4672
the oil seal (Fig.
Fig. 2-62
Removing Oil Seal
2000 RTF Service Manual
(12) Remove the teflon seal from the piston (Fig. 2 — 63).
(13) Remove the o-ring on the piston (Fig. 2 — 64).
/
/>
/ /Jÿ
( (14) Wash all the parts in solvent.
Dry with air only. Destroy the old seals and o-rings.
V/1 /
;
zjAaUJ B-3703
B-3689
Fig. 2 — 63
1.
/7
Removing Teifon Seal
Fig. 2 — 64
Removing O-Ring
Wiper
2. Seal 3. Cap 4. Seal 5. Spacer 6. Rod 7. Back-Up Ring 8. Packing 9. Wear Ring 10. Case
5S B-589 1
— 65
Lift Cylinder Assembly
2
Z1
. Case 2. O-Ring 3.
Stop Nut
4. 5. Piston Seal 6. O-Ring 7. Piston 8. Back-Up Ring 9. Head 10. Seal
/4
3
/
Wffi®
/>/67 -
1 . Wiper 12. Rod
Fig. 2-66
1. 2. 3. 4. 5.
Resle
Fig. 2
C-2698
Tilt Cylinder Assembly
1*1 ll1 ?
Case Nut Piston
6 7
/
O-Ring Piston Seal O-Ring Back-Up Ring Head
9. Seal 10. Wiper 1 1 . Rod
Fig. 2-67
C-2699
Steering Cylinder Assembly
68 of 252
-2-28-
2000 RTF Service Manual
2—10.12 Assembly of the Hydraulic Cylinder
Make an inspection of the
(1)
for scratches, nick, bent etc. Replace the parts as needed (Figs. 2-65, 2-66, 2 — 67).
parts
B-3682
(2)
Install piston.
o-ring
on
the
Installing the Oil Seal
Put the teflon seal in warm
water until it is soft and
stretches.
(4) Put the teflon seal on the piston. Install a hose clamp over the teflon seal and tighten. Leave the clamp in place for 5 minutes so the teflon seal will become the correct size.
jr
Fig. 2
— 69
8-3702
Installing Wiper Seal or Rod Seal on Tool
Resle
(3)
the
(5) Install the wiper seal with the lip toward the outside of the end cap (Fig. 2 68).
—
Installing Wiper Seal or Rod Seal
NOTE:
The o-ring side of the oil seal goes toward the inside of the cylinder.
(7) Install the oil seal on the rod seal tool (Fig. 2 — 69) and install the oil seal in the end cap (Fig. 2 — 70).
(8) Install the rod wiper (wiper seal) on the rod seal tool (Fig. 2 — 69) and install it in the end cap (Fig. 2 70).
—
-2-2969 of 252
2000 RTF Service Manual
Install the back-up washer (Fig. 2-71).
(9)
(10) Install the o-ring (Fig.
2 — 72).
(11) Put oil on the wiper seal and
install the cap on the shaft (Fig. 2-73).
(12) Remove the piston from the tool and install the piston on the shaft (Fig. 2 — 74).
B-368 1
B-3679
Fig. 2-71
Installing Back-Up Washer
Fig. 2-72
Installing O-Ring
(13) Install the nut and tighten to the following torque depending on which cylinder is being repaired (Fig. 2-75).
Steering Cylinder — 190-210 ft. -lbs. (258 - 284 Nm) Tilt Cylinder - 190 - 210 ft. -lbs. (258 - 284 Nm)
(14) Inspect the cylinder bore for scratches. Use a hone to clean up the cylinder bore.
3692
B-3685
Fig. 2-73
Fig. 2-74
Installing End Cap
Installing the Piston
(15) Put oil on the seals, o-rings and end cap threads (Fig. 2 — 76).
Resle
(16) Install the assembly in the cylinder housing (Fig. 2 — 77).
(1 7) Tighten the end cap with the special tool (Fig. 2 — 78).
(18) Push the cylinder rod in and out the full length of the cylinder housing. It must travel freely
through the full stroke of cylinder with no binding.
the
B-369 1
B-3670
Fig. 2-75
Fig. 2-76
Tighten the Nut
Putting Oil on the Seals
If the cylinder has binding, check for the following causes: A. B. C.
Rod is bent. End cap is damaged. Case is dented.
2-11 STEERING CONTROL VALVE The steering control valve is an open control valve that controls the operation of the steering cylinder. The center
steering wheel is fastened directly to the steering control valve.
70 of 252
B-5025
B-3665
Fig. 2-77
Installing the Assembly
-2 — 30-
Fig. 2-78
Tighten End Cap
2000 RTF Service Manual
2—11.1 Removing the Steering Control Valve
AWARNING
Install the steering frame lock before removing the steering control valve so that the machine does not move at the articulation joint.
B-5663
Lower the vertical mast and stop the engine.
(1)
Install the
(2)
steering
Fig. 2-79
Removing Steering Valve
frame
lock. (3) Remove the fioormat and floorpanel (See Paragraph 5 — 3.1, Page 5— 1 ). (4) Remove the covers (both inside and outside) over the control vaive. (5)
(6) Loosen the two elbow fittings. Turn the fittings so that you can reach the bottom two tubelines.
Fig. 2-80
1. 2. 3. 4.
5.
Disconnect the bottom two tubelines. (7)
(8)
Remove the steering control valve assembly from the machine (Fig. 2-79).
B-5665
B-5664
6.
Fig. 2-81
Removing Bolts
Seal Retaining Ring Seal Gland Bushing Seal Quad Ring Seal Needle Bearing Kit Bearing Race Needle Thrust Bearing Set Screw
7. 8. 9. 10. Seal 11 . Check Ball Seat 12. Seal 13. Check Ball 14. Check Ball Retainer 15. Control Parts Assembly
16. 1 7. 18. 19. 20. 21.
Removing Steering Wheel
Housing Control Sleeve Control Spool Centering Springs Centering Pin Seal
Resle
Disconnect the connections both sides of the top two tubelines.
at
22. Spacer Plate 23. Drive 24. Gerotor (Meter) 25. Spacer(s) 26. End Cap 27. Cap Screw
(9) Remove the 3 bolts that fasten the steering wheel to the steering control valve (Fig. 2 — 80).
(10) Remove the steering wheel from the steering control valve (Fig. 2-81).
2—11.2 Disassembly of the Steering Control Valve NOTE:
o
—
Figure 2 82 shows the steering control valve parts assembly and is used for reference only. Use the following procedure for the disassembly and repair of the control valve.
C-2692
Fig. 2-82
Steering Control Valve Assembly
-2-3171 of 252
2000 RTF Service Manual
IMPORTANT
NOTE:
Make sure to clean the unit disconnecting the tubelines or Work in a clean area disassembling the steering valve.
before hoses. when control
© ®.
Not all the figures show the steering control valve in the vise, it is recommended that you keep the control valve in the vise during disassembly.
(1) Install the steering control valve in the vise with the meter end of the control valve up (Fig. 2 — 83). Use protective material on the jaws of the vise. Do not overtighten the vise.
Fig. 2-83
Steering Valve in the Vise
(2) Remove the bolts from the steering control valve (Fig. 2 84, Item 1 ).
—
Resle
(3) Remove the end cap (Fig. 2-84, Item 2).
B-5564
Remove the seal from the end cap (Fig. 2 — 84, Item 3). (4)
Fig. 2-84
Removing End Cap
(5) Remove the meter from the housing (Fig. 2 85, Item 1). Be careful and do not drop the star which is in the meter.
—
CD (6)
Remove the seal from the 2 — 85, Item 2).
meter (Fig.
B-5563
(7)
Remove the drive spacer (Fig. 2 — 86, Item 3).
72 of 252
Fig. 2-85
Removing the Meter
-2-32-
2000 RTF Service Manual
(8) Remove the drive from the housing (Fig. 2 — 86, Item 1).
(9) Remove the spacer plate (Fig. 2 — 86, Item 2).
(10) Remove the seal from the housing (Fig. 2 — 86, Item 3).
B-5565
Fig. 2-86
Removing Drive and Spacer Plate
(11) Remove the housing from the vise and put it on a soft clean cloth to protect the surface finish.
(12) Use a small screwdriver and pry the retaining ring from the housing (Fig. 2 — 87),
B-5568
(13) Turn the spool and sleeve until the pin is in the horizontal position. Push the spool and sleeve assembly forward with your thumbs, just far enough to free the gland bushing from the housing
Fig. 2-88
Removing Gland Bushing
B-5552
(14) Remove the gland bushing
from the assembly.
spool
and
sleeve
Resle
(Fig. 2-88).
Fig. 2-87
Removing Retainer Ring
A-2800
(1 5) Remove quad ring
from the gland bushing (Fig. 2 — 89, Item 1 ]
Fig. 2-89
Removing Quad Seal
(16) Use a small screwdriver to remove the dust seal from the gland bushing (Fig. 2 — 89, Item 2). Do Not damage the bushing.
0 (17) Remove the two bearing races and the needle thrust bearing from the spool and sleeve assembly (Fig. 2 — 90).
8-5567
Fig. 2-90
Removing Thrust Bearing
-2-3373 of 252
2000 RTF Service Manual
(18) Remove the spool and sleeve assembly from the end of the housing with the 14 holes (Fig. 2-91). ÿr
—
~r-\
ÿ-Mj
IMPORTANT
'ÿÿÿÿ
.
r\
A-2793
B-5566
Fig. 2-91
Be careful that the parts do not tilt out of position while removing them. Turn the spool and sleeve assembly slowly and remove from the housing at the same time.
Removing Spool & Sleeve Assy,
Fig. 2-92
Removing the Pin
(19) Push the pin from the spool and sleeve assembly (Fig. 2 — 92).
(20) Push the spool part of the way out of the control end of the sleeve (Fig. 2 — 93).
B-5553
B-5553
Fig. 2-93
Positioning the Spool
Fig. 2-94
Removing the Centering Spring
(21 ) Be careful. Remove the six centering springs from the spool (Fig. 2 — 94).
— 95), turn the
Resle
(22) Push the spool back through and out of the sleeve (Fig. 2 spool slowly when removing it from the sleeve.
(23) Remove the seal from the housing (Fig. 2 — 96, Item 1).
(24) Remove the set screw (Fig. 2 — 96, Item 2) from the housing. B-5553
Fig. 2-95 (25) Using a machine bolt (1/8"
Removing the Spool
-
24) turn it into the end of the check ball seat. Then pull the machine bolts, with a pliers, to remove the seat from the housing (Fig. 2 — 96, Item 3).
(26) Turn the housing over to remove the check ball and check ball retainer (Fig. 2-96, Items 2, 4 & 5).
0
2—11.3 Inspection of the Steering Control Valve Check all the matching surfaces. Replace any parts that have scratches or burrs that can cause leakage. Clean all the metal parts in a clean solvent. Use air pressure to dry the parts. Do Not use cloth or paper towels because debris or other material can get into the system and cause damage. Do not grind or file on any of the parts.
-2-3474 of 252
B-5554
Fig. 2 — 96
Removing Seat & Check Bali
2000 RTF Service Manual
—
2 — 11.4 Assembling the Steering Control Valve
NOTE:
Lubricate all the seals (except the new quad ring seal) with clean petroleum jelly. Always use new seals when assembling the steering control valve.
®
(1 ) Use a needle nose pliers and install the check ball retainer (Fig. 2 — 97, Item 1 ) into the check valve hole in the housing. Make sure the retainer is straight in
the housing.
(2)
Install the check ball in the housing (Fig. 2 — 97, Item 2).
Lubricate the 5/8" (1 5,9 mm) diameter seal (Fig. 2 — 97, Item 3) and the 7/16" (1 1,1 mm) diameter seal (Item 4) and install on the check ball seat (Item
(3)
Fig. 2-97
Installing Check Valve
5).
(4) Lubricate the check ball seat and seals thoroughly, before installing in the housing. Do not turn or damage the seals when installing in the housing. Install the check ball seat in the housing, open end first and push the seat to the bottom of the hole.
_
100 in-lbs. (1 1
Control Sleeve (6)
Assemble the spool and sleeve carefully so the spring holes align at the same end (Fig. 2 — 98). Rotate the spool while sliding the two parts together. Test for free rotation. The spool must rotate smoothly in the sleeve.
Spring Slot
Spring Slot
Control
Resle
(5) Install the set screw (Fig. 2 — 97, Item 6) and tighten to Nm) torque.
Spool
Identification Marks (7)
Put the centering springs holes in alignment at the end of the spool and sleeve.
Fig. 2-98
NOTE: A special installation tool will be needed to install the centering springs in the spool and sleeve assembly. Make a tool as shown in figure 2 — 99 using 1/4" key stock material.
A-2794
installing Spool
6
0.240"
0.110" (2,8 mm)
Install the tool through the centering spring hole.
A-2802
(8)
Fig. 2-99
Installation Tool Dimensions
-2-3575 of 252
2000 RTF Service Manual
(9) Position 3 pairs of centering springs on the bench so that the extended edge of the springs is down and the arched center section is together. In this position, install the centering springs into the end of the installation tool (Fig.
2-100).
(10) Compress the ends of the centering springs set and push into
Fig. 2— 100
Installing Centering Springs
the spool and sleeve assembly and pull the installation tool out at the same time.
(11) Center the spring set in the spool and sleeve assembly so that they push down evenly and are even with the upper surface of the spool and sleeve.
A-2793
Fig. 2-101
Installing Pin
Resle
(12) Install the pin through the spool and sleeve until the pin is even at both sides of the sleeve (Fig. 2—101).
(13) Position the spool and sleeve so that the splined end of the spool enters the 1 4 hole side of the housing (Fig. 2— 1 02).
B-5566
Fig. 2—102
IMPORTANT
Be careful that the parts do not tilt out of this position while installing them. Push the parts gently into position with a small rotating action, keep the pin in the horizontal position. Install the spool assembly into the housing bore until the assembly is even at the meter end of the housing. DO NOT pull the spool assembly beyond this position to prevent the cross pin from dropping into the discharge port of the housing. With the spool assembly in this position, it must rotate freely.
-2-3676 of 252
Installing Spool & Sleeve
2000 RTF Service Manual
(14) Put the housing on a clean, lint free cloth. Install the 2-1/8" (54 mm) diameter seal (Fig. 2—103, Item 1) in the housing.
(1 5) Install the two bearing races (Fig. 2—103, Item 2) and the needle thrust bearing (Item 3) in the housing.
(1 6) Install the 1-1/4" (31 ,6 mm) diameter dust seal in the seal gland bushing, flat or smooth side of the dust seal must face down toward the bushing (Fig.
2-104).
A-2797
Fig. 2
— 103
Installing Bearing
Install the dry quad ring seal in the seal gland bushing. Push the seal into position with your finger. Do not use any seal that falls freely into the pocket of the bushing (Fig. 2—105). (1 7)
MD (18) Install the seal gland bushing (Fig. 2 — 105) over the spool end with a
rotating motion. Tap the bushing into position. Make sure the bushing is against the bearing race.
#st
(19) Install the retainer ring (Fig. 2—103, Item 1) in the housing. Tap the retainer ring around the circumference of the ring to make sure it is position
ms>
H
x/Cÿtr
N
Fig. 2-104
rfSffc
JD
//
/y>N A-2798
Installing Gland Bushing
(20) Install the housing in the vise.
Make sure that the spool and sleeve assembly are even with the 14 hole surface of the housing.
Screwdriver Dust Seal Retaining Ring Seal Gland Bushing Quad Ring Seal
IMPORTANT Clean the upper surface of the housing by wiping with the palm of a clean hand. Clean each of the flat surfaces of the meter section in the same way when assembling. DO NOT use cloth or paper to clean the surfaces.
A-2799
Fig. 2-105
Gland Bushing Installation
-2-3777 of 252
2000 RTF Service Manual
Resle
correctly.
3" (76,2 mm) diameter seal (Fig. 2—106, Item 1 ) in the housing.
(21) Install the
&&&
(22) Install the spacer plate (Fig. 2—106, Item 2). Make alignment of the bolt holes in the spacer plate
with the tapped holes in the housing. B-5569
B-2796
Fig. 2—106
Installing Spacer Plate
Fig. 2-107
Installing Drive
(23) Rotate the spool and sleeve assembly until the pin is parallel with the port face (Fig. 2— 107).
(24) Install the drive, make sure you engage the drive into the pin (Fig. 2—1 07).
(25) Install the 3" (76,2 mm) diameter seal on the meter (Fig. 2
— 108, Item 1 ) A- 2 7 9 5
Fig. 2-108 (26) With the seal side of the meter toward the spacer plate, make alignment of the star valleys (Fig. 2—109, Item 1) on the drive (Item 2).
Meter (Gerotor) star Valley
Resle
NOTE:
Installing Meter
Make sure there is a parallel relationship of reference "A", "B", "C" and "D" (Fig. 2 — 109). Make alignment of the bolt hole in the meter unit without disengaging the meter from the drive.
Drive (Marked)
(27) Install the drive spacer.
(28) Install the 3" (76,2 mm) diameter seal on the end cap.
(29) Install the end cap on the housing, make alignment of the bolt holes.
B-5556
Fig. 2-109
Timing the Steering Control Valve
-2-3878 of 252
2000 RTF Service Manual
(30) Install the 7 bolts dry in the end cap. Pre-tighten the bolts to 1 50 in.-lbs. (1 7 Nm) torque in the sequence shown in figure 2—1 10, then tighten the bolts to 275 in.-lbs. (31 Nm) torque in the same sequence as shown in figure
2-110.
2— 11.5 Installing the Steering Control Valve ( 1)
Install the steering wheel on the steering control valve (Fig. 2 — 111).
(2) Make alignment of the three bolt holes and install the bolts and tighten (Fig. 2-112).
A-2801
Fig. 2-110 (3)
Install the steering control valve assembly into the machine (Fig. 2 — 1 13).
(4)
Connect the bottom two tubelines and tighten.
(5)
Turn the elbow fittings into the correct location and tighten.
(6)
Connect the top two tubelines and tighten (Fig. 2— 1 1 4).
(7)
Install the cover over the control valve.
(8)
Install the floorpanels and floormat.
(9)
Remove the steering frame lock.
Tighten Sequence
ill
B-5665
Fig. 2-111
installing Steering Wheel
r n
(10) Operate the forklift to check for correct operation of the steering controls.
1
A WARNING
Resle
> i sin After the steering control valve has been repaired DO NOT put your hands or arms through the steering wheel the first time you start the engine. If the steering control valve is not timed correctly, personal injury may result. B-5664
Fig. 2-112
Tighten the Bolt
Fig. 2-114
Tighten Tubeline
B-5663
Fig. 2-113
Installing Steering Assembly
-2-3979 of 252
2000 RTF Service Manual
Resle 80 of 252
HYDROSTATIC SYSTEM
CHARGE PRESSURE AND REPLENISHING VALVES FOOT PEDAL AND CENTERING MECHANISM HYDROSTATIC MOTOR HYDROSTATIC PUMP SERVO CONTROL CYLINDER SYSTEM OPERATIONS DESCRIPTION . TROUBLESHOOTING
ID
3-10
3-4 GO -O CO CO CO CO 3-1 GO to
3-7 3-26 3-12 CO ÿd3-1 3-2
CO
1
1
1
1
.
Page Number
I
I
A WARNING
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
A WARNING
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or damage eyes. Leaks of fluids under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use bare hand. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical attention.
HYDROSTATIC SYSTEM
Resle
Paragraph Number
2000 RTF Service Manual 81 of 252
Resle 82 of 252
3 HYDROSTATIC SYSTEM
3-1 SYSTEM OPERATIONS DESCRIPTION
NOTE:
See Chart # 6566660 for the following copy description.
The hydrostatic system has tandem pumps (2). They are engine driven, variable displacement pumps and they provide fluid flow to a fixed displacement hydrostatic motor (25).
Engine RPM is adjustable by a.throttle control and is constant. Machine speed and direction of travel is controlled by a foot pedal which adjusts the amount and direction of fluid flow from the hydrostatic pumps (2) to the hydrostatic motor (25). Fluid from the steering control valve (1) goes to the 40 micron filter (8) installed in the port block (9). Fluid goes through the port block (9) and to the center section of the hydrostatic pumps (2). This fluid is called "charge pressure fluid". In the center section of the hydrostatic pumps (2) the fluid is against four replenishing valves (3) and the charge relief valve (4).
When the fluid goes to the hydrostatic pumps (2), the replenishing valves (3) on the low (charge pressure) side of the pump will open and let the fluid into the pump for replenishing, lubrication and cooling.
The hydrostatic pumps (2) do not need the full volume of fluid flow, so there is extra fluid. This extra fluid goes to the charge relief valve (4). When the pressure reaches the setting of the charge relief valve (4), the valve will open and let the extra fluid go to the reservoir (17).
A foot pedal controls the speed and the direction of the machine's travel. Speed is controlled by adjusting the amount of fluid that goes to the hydrostatic motor (2), and the direction is controlled by changing the direction of fluid flow. The foot pedal is mechanically connected to a servo control cylinder (16) which controls both the amount and the direction of the fluid flow from the hydrostatic pumps (2) by adjusting the angle of the swashplates in the hydrostatic pumps (2).
Resle
So that there is enough pressure to operate the servo control cylinder (1 6), an orifice (7) is installed in the charge pressure line to the hydrostatic pumps (2). This causes higher pressure in the port block (9) and in the line to the servo control cylinder ( 1 6) for operation of the servo cylinder.
The hydrostatic pump (2) is a HI/LO combination pump. Two pairs of high pressure hoses go from the center section of the hydrostatic pumps (2) to the hydrostatic motors (25) manifold block (27). When the demand on the hydrostatic system is heavy and low speed, only one hydrostatic pump (2) is providing fluid for the system. When the demand is light at fast travel speed, both hydrostatic pumps provide fluid flow to the hydrostatic motor (25).
When the foot pedal is in neutral, the hydrostatic pumps (2) and the hydrostatic motor (25) are not working but do have charge pressure. When the foot pedal is moved, the swashplates are angled and the fluid is forced out of the pressure side of the hydrostatic pumps (2). This fluid flow is called "drive pressure fluid". Drive pressure fluid is much higher than charge pressure fluid which causes the replenishing valves (3) to close allowing the flow of the fluid to go to the hydrostatic motor (25). There is a shuttle valve (30) which moves, depending on the direction of the machine, and allows fluid to return to the "Tee" at the center section of the hydrostatic pumps (2) and to the oil cooler (24) for cooling. The shuttle valve (30) opens the charge pressure side of the loop to the stroked charge relief valve (26) which is located in the manifold block (27) on the hydrostatic motor (2 5). The relief valve (26) releases the extra flow when cooling is required in forward or reverse direction. When the machine is driven, with the vertical mast down, into a solid object there is resistance causing high fluid pressure in the drive loop. There are two high pressure drive relief valves (28) (one for forward and one for reverse) installed in the manifold block (27) of the hydrostatic motor (25). These relief valves (28) release the high pressure from the drive loop to protect the hydrostatic system.
There is a tow valve (29) located on the manifold block (27) of the hydrostatic motor (25). When the machine is unable to move with its own drive system, turn the tow valve (29) % turn to push the high pressure relief valves (28) off their seats so that the machine can be moved for a short distance at a low speed.
83 of 252
-3-1B-
2000 RTF Service Manual
3-2 TROUBLESHOOTING
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
Excessive noise in the hydrostatic pump.
1 , 2, 3, 4
Hydrostatic pump overheating.
1 , 4, 5, 6
System not developing pressure.
1, 7
Loss of fluid.
8, 9
Drive with light on.
1, 10, 1 1, 12.
No drive in one direction.
7, 13, 14, 15, 16
Forklift moves with foot pedal in neutral position.
14, 17
Slow or no drive.
7, 13, 14, 1 5, 18, 19, 20, 21, 22, 23, 24, 25
No forward high speed.
13, 14, 17, 26
Loss of hydrostatic power under load condition.
13, 23, 24, 25
Loss of charge pressure or partial loss.
14, 18, 19, 20, 21, 22, 23, 25, 27, 28
Hydrostatic motor free wheels.
28
-3-284 of 252
2000 RTF Service Manual
Resle
CAUSE
PROBLEM
3-2 TROUBLESHOOTING (Cont'd)
KEY TO CORRECT THE CAUSE 1.
Low fluid in the reservoir.
2.
Air in the system.
3.
Incorrect hydraulic fluid.
4.
Excessive internal wear.
5.
Oil cooler not working or dirty.
6.
Engine not being operated at correct RPM.
7.
High pressure relief valves not working correctly.
8.
Leaking tubelines.
9.
Hydrostatic motor seal leaking into the axle.
10. Pressure switch not working correctly. 1 1 . The #3 element is plugged. 12.
Hydrostatic fluid temperature too high.
13. Lack of charge pressure.
1 5.
Replenishing valve not working correctly.
1 6.
Shuttle valve in motor manifold is stuck.
Resle
14. Bad servo control.
17. Servo linkage not adjusted correctly.
18. Neutral charge relief valve is not working correctly. 19. Cold weather by-pass valve is not working correctly. 20.
The 40 micron filter is plugged.
21 .
Stroke charge relief valve is not working correctly.
22.
Hydraulic pump is not working correctly.
23.
Tow valve in open position.
24.
Bad hydrostatic motor.
25.
Bad hydrostatic pump.
26. The rear hydrostatic pump is not working correctly. 27.
Orifice is not in the charge tubeline.
28.
Contaminated particles holding the connector plate off back plate or cam.
-3-385 of 252
2000 RTF Service Manual
3-3 SERVO CONTROL 3 — 3.1 Neutral Adjustment for Servo Control
The wheels must not move when the foot pedal is centered. If the wheels move when the foot pedal is centered, you must adjust the servo control linkage for neutral position, use the following procedure to adjust the linkage: ( 1)
Lower the vertical lift. Stop the engine.
(2) Lift and block the machine (See Paragraph 1—2, Page 1—1 for correct procedure).
(3)
Make sure the foot pedal is in the center position. Start the engine.
NOTE: The back-up alarm will sound when the machine is in reverse. (4) If the wheels move then you must adjust the servo control linkage, do Steps 5 thru 1 2 to make the correct adjustment.
DO NOT stand on or near the
tires.
(5) Remove the floormat and the floorpanel (See Paragraph 5 5-1).
— 3.1,
Page
Remove the cotter pins (Fig. 3—1, Item 1) from the bolts (Item 2) in the clamps on each end of the linkage. (6)
(8)
the
Resle
(7) Loosen the bolts (Fig. 3—1, Item 2) and the nuts (Item 5 and Item 9).
Make sure the foot pedal is in center position. Start the
engine.
Turn the linkage rod (Fig. 3—1, Item 3) in both directions until the centered position is found and the wheels stop moving. (9)
(10) Stop the engine. (11) Tighten the bolt (Fig. 3—1, Item 2) and the nut (Item 9) to 1 5 ft. -lbs. (20 Nm) torque.
t
—
in
(12) Turn the nuts backward until the nearest slot is aligned with the hole in the bolts. Install the cotter pins (Fig. 3—1 , Item 1). (13) Tighten the nut (Item 5) to 75-90 ft. -lbs. (102-122 Nm) C-27 66
torque.
Fig. 3 — 1
Servo Control and Pedal Control
-3-486 of 252
2000 RTF Service Manual
(14) Install the floorpanels and the floormat (See Paragraph 5 — 3.2, Page 5—1 ).
NOTE:
If neutral can not be obtained, (See Paragraph 3 4.3).
—
3
— 3.2 Removing the Servo Control
To remove the servo control, use the following procedure:
Fig. 3 — 2
Hoses for Servo Control
Lower the vertical lift.
(2) Stop the engine. Lift and block the machine (See Section 1—2, Page 1 — 1 for the correct procedure).
(3)
Mark the hoses and fittings and remove the hoses (Fig. 3 — 2, Item 1 ) from the servo control (Item 2). Put plugs in the fittings. (4)
(5)
-ZD
Remove the floormat and floorpanels (See Paragraph 5 — 3.1, Page 5 — 1 ]
Disconnect the linkage (Fig. 3—1, Item 3) at the "H" bracket (Item
\
ZJfZD
4).
|r
rM! I
(6) Remove the two bolts that fasten the torsion bushings (Fig. 3 — 2, Item 3) on the base end and the rod end of the servo control.
(7)
Remove the servo control (Fig. 3 — 2, Item 2) from the machine.
3 — 3.3 Disassembly of Control
(1)
)
Fig. 3-3
C-2721
Removing Snap Ring
the Servo
Put the servo control in a vise.
(2) Using a snap ring pliers, remove the snap ring (Fig. 3 — 3)
from the housing.
(3)
Remove the rod and piston — 4, Item 1) from the housing. assembly (Fig. 3
B-5573
Fig. 3-4 Servo
Control
-3-587 of 252
2000 RTF Service Manual
Resle
(1)
(4)
Remove the button (Fig. 3 — 5) from the cap.
(5)
Using the Allen wrench, remove the cap (Fig. 3
— 6) from the housing.
(6) Remove the bolt (Fig, 3 — 4, Item 2) and spacer and the spool (Item 3) from the servo control housing.
(7) Clean and inspect all the parts for wear or damage. Replace the parts as needed.
3 — 3.4 Assembling the Servo Control Always use new o-rings and seals when assembling the servo control.
NOTE:
(1) Install the spool, spacer and bolt (Fig. 3 — 4, Item 2 & 3) in the servo housing. Put loctite adhesive on the bolt. (2) Install the cap (Fig. 3 — 6) on the housing and tighten with an Allen wrench. Put loctite adhesive on the cap. (3)
Install the button (Fig. 3—5) in the cap.
(4)
Install the piston and rod assembly (Fig. 3 — 4, Item 1) into the housing.
(5)
Install the snap ring (Fig. 3 — 3) into the housing.
Fig. 3-5
Removing the Button
3 — 3.5 Installing the Servo Control If a new servo control is installed, remove the "H" bracket and the mount with bushings from the old servo control. Install them on the new servo control. Use loctite on all threads and tighten the bolt (Fig. 3 — 7, Item 1) to 20 ft. -lbs. (27 Nm) torque. Tighten the Allen screw (Item 2) to 8 ft. -lbs. (10
NOTE:
(1)
Install the servo control in position on the pintle lever.
(2)
Install the washer and nut (Fig. 3—1 , Item 5) but do not tighten.
Resle
Nm) torque.
B-5575
Fig. 3-6
Removing the Cap
(3) Rotate the servo control until the mount and torsion bushing are in the clevis of the servo control mount. If there is binding on the servo control rod as it is rotated into place, loosen the three bolts holding the servo control mount in place and rotate the mount. Tighten the bolt (Fig. 3—1, Item 6) to 28 - 35 ft.-lbs. (47 - 54 Nm) torque. Tighten the bolt (Item 7) to 54 - 60 ft. -lbs. (73 - 81 Nm) torque. Tighten the bolt (Item 8) to 75 - 85 ft. -lbs. (1 02 - 1 1 5 Nm) torque.
NOTE:
Be sure to tighten the bolts on the servo control mount in this order to avoid movement of the mount while tightening bolts.
(4)
Install the bolt, nut (Fig. 3—1 , Item 9) and cotter pin.
(5)
Adjust the servo control for neutral position (See Paragraph 3 — 3.1).
(6) Tighten the nut (Fig. 3 — 1, Item 5) to torque.
75 - 90 ft. -lbs. (102 - 122 Nm)
(7)
Connect the hoses to the servo control and hoses.
(8)
Connect the linkage (Fig. 3 — 8, Item 4).
B-6055
88 of 252
Fig. 3
-3-6-
—7
installing "H" Bracket
2000 RTF Service Manual
3-4 FOOT PEDAL AND CENTERING MECHANISM 3 — 4.1 Adjusting Foot Pedal Angle
The angle of the foot pedal (Fig. 3 — 8, Item 1) can be adjusted for operator comfort. Use the following procedure for the correct adjustment: (1)
Disconnect the foot pedal linkage (Fig. 3 — 8, Item 2) from the foot pedal (Item 1) and the centering mechanism (Item 3). i
Lengthen the linkage to increase the angle of the foot pedal. Shorten the linkage to lower the angle of the foot pedal. (2)
(3) Connect the linkage to the foot pedal and the centering mechanism.
3 — 4.2 Removing the Mechanism
—
---
-
Centering
Remove the floormat and floorpanels from the machine (See Paragraph 5 — 3.1, Page 5—1). (1)
Fig. 3-8
«'
C-2766
Foot Pedal and Centering Mechanism
Disconnect the foot pedal linkage (Fig. 3 — 8, Item 2) from the centering mechanism.
(2)
Resle
(3) Disconnect the servo control linkage (Fig. 3 — 8, Item 4) from the centering mechanism. (4) Remove the two bolts that fasten the centering mechanism to the machine frame.
3
(5)
Unplug the wires from the neutral safety switch.
(6)
Remove the centering mechanism from the machine.
— 4.3 Adjusting the Springs In the Centering Mechanism (1)
Put the centering mechanism in a vise.
(2) Loosen the two nuts (Fig. (Item 2) to the bracket. (3)
3 — 9, Item 1) which lock the adjusting bolts
Move the linkage arm (Fig. 3 — 9, Item 3) to the center of travel.
—
(4) Move the adjusting bolts (Fig. 3 9, Item 2) firmly against the ends of the springs (Item 4) so there is no clearance between the ends of the springs and the
adjusting bolts. i-5576
(5)
Tighten the nuts (Fig. 3 — 9, Item 1) on the adjusting bolts.
-3-789 of 252
Fig. 3-9
Centering Mechanism
2000 RTF Service Manual
3—4.4 Replacing the Springs on the Centering Mechanism (1) Remove the nut (Fig. 3 — 10, Item 1) from the ball stud (Item 2) on the neutral safety switch.
Disconnect the safety switch from the centering mechanism arm. (2)
linkage
Remove the two bolts and 3 — 10, Item 3) from the bracket which fastens the neutral safety switch to the centering mechanism. (3)
nuts (Fig.
(4) Remove the neutral safety switch from the centering mechanism.
-5489
Fig. 3-10
Centering Mechanism
(5) Remove the two adjusting bolts (Fig. 3 — 9, Item 2).
Remove the two spring stop bolts (Fig. 3 — 9, Item 5).
(6)
(7) Remove the four (4) bolts and nuts (Fig. 3—1 1, Item 1) that fasten the shaft bearing to the bracket. (8)
Remove the bearings (Fig. 3—11, Item 2) from the shaft.
(9)
Remove the linkage shaft and the springs (Fig. 3— 1 2).
(10) Remove the springs from the shaft and replace as needed.
bracket.
Resle
(11) Install the springs and shaft into the
( 1 2) Install the bearings at each end of the shaft (Fig. 3—1 1 ).
(13) Install the four bolts and nuts into the bearings and tighten. (14) Install the spring stop bolts (Fig. 3 — 9, Item 5).
B-5577
Fig. 3-11
Centering Mechanism Bearings
NOTE: Tighten the springs beyond the stop bolts before installing the bolts. (1 5) Install the two adjusting bolts. (16) Adjust the centering mechanism for center position (See Paragraph 3-4.3). (1 7) Install the neutral safety
switch and bracket in the centering mechanism.
(18) Install the two bolts and nuts (Fig. 3—10, Item 3) into the bracket and centering mechanism. ( 1 9) Put loctite on 23 Nm) torque.
the bolts and tighten the nuts
to 1 80 to
200 in.-lbs. (21 to
(20) Install the ballstud (Fig. 3—10, Item 2) in the centering mechanism arm. (21)
Put loctite on the nut (Fig. 3— 1 0, Item 1 ) and tighten.
(22) After the centering mechanism is installed in the machine, adjust the neutral safety start switch (See paragraph 3 — 4.6).
90 of 252
-3
—
8-
B-557
Fig. 3-12
Removing Linkage Shaft
2000 RTF Service Manual
3—4.5 installing the Centering Mechanism ( 1)
Put the centering mechanism in the correct location in the machine.
(2)
Align the holes and install the two bolts and tighten the nuts.
(3)
Connect the foot pedal linkage and the servo control linkage. Tighten the
nuts and install the cotter pins.
(4) Adjust the servo control linkage for neutral position (See Paragraph 3-3.1).
3—4.6 Adjusting the Neutral Safety Start Switch The neutral safety switch will prevent the machine from being started unless the foot pedal is in the neutral position. Use the following procedure to adjust the neutral safety switch: ( 1)
Lower the verticle lift and stop the engine.
(2)
Lift and block the machine (See Section 1 — 2, Page 1 — 1 ). Install the frame
lock. (3) Make sure the foot pedal is in the neutral position (See Paragraph 3 — 3.1 for adjustment of the servo control linkage). (4) Loosen the clamp and move the rubber boot down so the shaft and the end of the switch housing shaft (threads) (Fig. 3—13, Item 4) are visible.
The boot is not pictured in figure 3—13 so that other parts of the neutral safety start switch can be pictured clearly.
Resle
NOTE:
Loosen the locknut (Fig. 3 — 13, Item 1) on the end of the neutral safety switch (Item 2). (5)
(6) Turn the shaft (Fig. 3 — 13, Item 3) until the line (Item 4) on the shaft is even with the switch body. (7)
Tighten the locknut.
(8) Fasten the rubber boot with the clamp.
(9) Move the foot pedal from the neutral position and try to start the engine, if the engine starts, do the procedure again.
NOTE:
When the neutral safety switch is adjusted, the back¬ up alarm will also be adjusted correctly.
B-5488
Fig. 3-13 Neutral Safety
-3-991 of 252
Switch Adjustment
2000 RFT Service Manual
3-5 CHARGE PRESSURE AND REPLENISHING VALVES
3 — 5.1 Checking the Charge Pressure (1 )
Lower the vertical lift and stop the engine.
Install the steering frame lock, lift and block the machine (See Section 1-2, Page 1-1).
(2)
(3)
Remove the floormat and floorpanels (See Paragraph 5 — 3.1, Page 5 — 1 ).
(4) Remove the plug (Fig. 3—14, Item 1) from the port block and install a pressure gauge.
(5)
Start the engine and run it at 2600 RPM.
(6)
The pressure gauge must read as is listed in the chart below.
Fig. 3-14
Checking Charge Pressure
CHARGE PRESSURE Pintle Position
Neutral
1 50°F (63°C) Fluid
260 (1793
Stroked*
225
- 280 PSI - 1931 kPa) - 235 PSI
(1552 - 1620 kPa)
1 20°F (39°C) Fluid
265 (1827
- 285 PSI - 1965 kPa)
230 - 240 PSI (1586 - 1655 kPa)
NOTE:
(7)
If the charge pressure is not correct, go to paragraph 3 orifice size.
Resle
'The hydrostatic pumps must be stroked with the machine lifted and blocked.
— 5.2 and check the
Remove the pressure gauge and install the plug in the port block.
(8) Install the floorpanels and the floormat (See Paragraph 5-1).
5 — 3.2, Page
A-2838
Fig. 3-15
Tubeline Orific
3 — 5.2 Checking Orifice in Charge Tubeline (1) Remove the floormat and 5-1).
the floorpanels (See Paragraph 5 — 3.1, Page
(2) Loosen the fitting and remove the tubeline from the port block (Fig. 3—1 5, Item 1 ).
(3)
Remove the orifice from the tubeline (Fig. 3—15, Item 2).
(4) Using a dial caliper, check the orifice size (Fig. 3—16). The correct hole diameter for the orifice is 0.21 7 - 0.225" (5,51 - 5,72 mm).
-3-1092 of 252
A-2837
Fig. 16 Checking Orifice Size
2000 RTF Service Manual
(5) Install the orifice in the tubeline end, install the tubeline and tighten the fitting.
(6) Install the floorpanels and the floormat (See Paragraph 5 5-1).
(7)
— 3.2,
Page
Check the level of fluid in the reservoir and add the correct fluid to the level (See Specifications Section for the correct fluid).
correct
3
— 5.3 Replenishing Valves
There are four replenishing valves installed in the center section of the hydrostatic pumps. One valve is installed under each high pressure hose and is internally connected to the hose port.
Depending upon the machine's direction of travel, the hoses may be either on the high pressure side or low pressure side of the system. When a hose is on the low pressure side of the system, the replenishing valve opens to allow replenishing fluid to flow into the system (Fig. 3 — 17, Function 1). When a hose is on the high pressure side of the system, the replenishing valve closes keeping high pressure fluid in the system (Fig. 3—17, Function 2).
Charge Fluid
ÿ Function 1 Valve Moves For Charge Fluid Replacement
To check the replenishing valves, use the following procedure:
Lower the vertical lift and stop the engine.
--
Bi
ÿÿ33
'
o
(2)
Install the steering frame lock. Lift and block the machine (See Section 1-2, Page 1-1). Function 2
From under the machine, remove the four replenishing valves from the center section of the hydrostatic pumps (Fig. 3—1 8).
B-2805
(3)
Fig. 3-17
Replenishing Valve Operation
(4) Clean and inspect the valves for damage and replace the valves as needed.
ÿ==ÿ===i-=== (5)
Install the valves, springs and
plugs.
\
I
Check the level of fluid in the reservoir and add the correct fluid to the correct level (See Specifications for the correct (6)
I
I
fluid).
(7) Start the engine and check the operation of the hydrostatic
system.
[
_
_ I
I
i
B- 558 1
Fig. 3-18
Replacing the Replenishing Valve
-3-1193 of 252
I
I
2000 RTF Service Manual
Resle
(1 )
3-6 HYDROSTATIC PUMP
3—6.1 Removing the Hydrostatic Pump
Use the following procedure to remove the hydrostatic pump from the machine:
(1)
Lower the vertical lift and stop the engine.
Install steering frame lock. Lift and block the machine (See Section 1 —2, Page 1-1).
(2)
Fig. 3-19
NOTE:
Heat Shield Bolts
Make sure there is a least 22" (559 mm) under the rear of the machine frame so that the rear axle can be removed.
(3) Remove the fluid from the reservoir.
(4) Remove the floormat and the floorpanels (See Paragraph 5-3.1, Page 5-1).
(5) Remove the seat and the seat plate assembly from the machine (See Paragraph 5 — 4.1, Page 5-2).
Remove the rear axle and the hydrostatic motor as an assembly from the machine (See Paragraph 4-5.2, Page 4-2). (7)
Fig. 3-20
Resle
Rear of Machine
Remove the fuel tank from the machine (See Paragraph 5-5.1, Page 5-3). (6)
Removing the Heat Shield and Screen
Mark and disconnect all the hoses and the tubelines from the hydrostatic pump. Put plugs or caps in all the openings.
(8)
(9) Remove the bolts that fasten the engine shields (one on each side of the hydrostatic pump) and the screen (Fig. 3—19).
( 1 0) Remove the shields and the screen from the machine (Fig. 3 — 20) through the bottom of the machine.
(11) Disconnect all the electrical connections.
(12) Remove the snap rings and loosen the two bolts that fasten the pintle arms to the shaft (Fig. 3 — 21 ) of the pump.
-3-1294 of 252
B-5584
Fig. 3-21 Pintle Arm Bolts
2000 RTF Service Manual
(13) Remove the two bolts (Fig. 3 — 22) and remove the pump mounting bracket from the right side of the hydrostatic pump.
(14) Remove the locknut at the ballstud at the front of the servo control cylinder linkage.
(15) Disconnect the linkage from the centering mechanism.
(16) Remove the bolt at the rod end of the servo control.
5586
Fig. 3-22
Removing Pump Mounting Bracket
Fig. 3-23
Removing Left Mounting Bracket
Fig. 3-24
Removing Mounting Bolts
(17) Remove the upper bolt from the shock absorber.
(1 8) Remove the pintle arms from the pintle shafts.
Resle
(19) Remove the pintle arm, servo control cylinder and shock absorber assembly from the machine.
(20) Remove the two bolts that fasten the left pump mounting bracket (Fig. 3 — 23).
(21) Remove the pump mounting bracket from the machine.
(22) Remove the two bolts that fasten the pump to the rear pump mounting bracket (Fig. 3 — 24).
(23) Put the sling around the operator cab and hook a chain hoist to the sling (Fig. 3 — 25).
(24) Install a chain on the hydrostatic pump and hook it to the sling. Lower the pump from the machine to the floor.
-3-1395 of 252
Fig. 3-25
Removing the Hydrostatic Pump
2000 RTF Service Manual
—
3 6.2 Disassembly of the Hydrostatic Pumps
IMPORTANT Keep all the hydrostatic parts clean. Dirt in the system will cause damage in a short period of time.
B-499
Fig. 3-27
Removing Pump Snap Ring
B-5996
NOTE:
If o-rings, gaskets and shaft seals are removed use new parts for assembly.
Fig. 3 — 26
Marking Pump Section
The tools listed will be needed to do the following procedure:
MEL- 1188
Socket
(2) Remove the hydraulic pump from the end of the hydrostatic pumps (See Paragraph 2 — 8.2).
Resle
(1) Remove all the tubelines from the hydrostatic pumps.
B-4997
Fig. 3-28
Removing Pump Bolts
(3) Put a mark across all the pump sections for correct assembly (Fig. 3 — 26).
(4) Remove the snap ring (Fig. 3 — 27), the collar from the spline and the vane pump drive shaft.
w
(5) Remove the six bolts that hold the hydrostatic pump to the center section (Fig. 3 — 28).
Remove the hydrostatic pump housing (Fig. 3 — 29).
B-4978
(6)
Fig. 3-29
Removing Pump Housing
2000 RTF -3-1496 of 252
Service Manual
(7) Remove the wafer plate (Fig. 3 — 30). Make note of its position for correct assembly.
Remove the gasket, bearing and bearing spacer (Fig. 3 — 31).
(8)
8-281 7
B-5053
Fig. 3-30
Fig. 3-31 Removing Bearing & Spacer
Removing Wafer Plate
IMPORTANT Keep ail the parts for one pump separate from parts for the other pump.
op
CT
-4992
Fig. 3-32
Removing Rotating Group
Fig. 3-33
Marking Rotating Group
Resle
(9) Remove the rotating group from the housing. Use both hands to keep the pistons from falling out of the cylinder block (Fig. 3 — 32).
(10) Put a mark on one of the
pistons and on one cylinder bore (Fig. 3 — 33) and remove the pistons from the cylinder block.
B-4974
B-4988
Fig. 3-34
Fig. 3-35
Marking Pintle Side
Removing Pintle Cover
(11) Mark the pintle lever side of the pump housing (Fig. 3 — 34).
(12) Remove the four bolts that hold the pintle covers on each side of the pump housing (Fig. 3 — 35 & 3-36).
B-4980
Fig. 3-36
Removing Pintle Cover
-3-1597 of 252
2000 RTF Service Manual
(1 3) Remove the pintle cover and the shims (Fig. 3 — 37 & 3 — 38).
IMPORTANT
B-4960
Fig. 3-37
B-4966
Fig. 3-38
Removing Pintle Cover
Removing Pintle Cover
Be sure not to damage shims under pintle covers. If shims are damaged, the shims must be replaced with shims of the exact same thickness (unless new bearings are installed).
B-4993
Fig. 3-39 (14) Remove the 3-40).
o-rings
Removing O-Ring
B-5049
Fig. 3-40
Removing O-Ring
Fig. 3-42
Removing Bearing Spacer
(Fig.
Resle
3-39 &
(15) Remove the bearing spacers
from
the
pump
housing
(Fig.
3-41 & 3-42). -505
Fig. 3-41
Removing Bearing Spacer
(16) Move the yoke from side to side to loosen the bearing races. Remove the races and the bearings (Fig. 3-43).
the yoke at an angle and and yoke together (Fig. 3 — 44). ( 1 7) Turn
remove the shaft
Fig. 3-43
Removing Races & Bearing
-3-1698 of 252
-4979
-5050
Fig. 3
— 44
Removing Yoke & Shaft
2000 RTF Service Manual
(18) Use a press to remove the bearing from the drive shaft (Fig. 3 — 45) and bearing race from the pump housing.
NOTE:
Use the same procedure to disassemble the other pump.
8-5016
Fig. 3-46 Shaft
Inspection
IMPORTANT i-501 5
Keep parts for each pump separate. Some parts will fit both pumps but must not be used in the other pump because of specific wear patterns.
Fig. 3-45
Removing the Bearing
B-5027
3 — 6.3 Hydrostatic Pump Inspection Fig. 3-47
Wafer Plate Inspection
Check the shaft and the collar for wear and damage to the splines (Fig. 3-46). (1)
(2) Check the wafer plate for wear and damage (Fig. 3 47). If groves can be felt on the surface with your fingernail, replace the wafer plate. Make sure the wafer plate is flat against the manifold
Resle
—
block.
(3) Check the bearings for wear and heat damage (Fig. 3 — 48). Check the bearing spacers for sharp edges.
Check each piston in its cylinder (Fig. 3 — 49). The piston must move freely in the cylinder bore. If the piston does not move freely, clean the piston and the bore and put oil on the pistons and (4)
try again.
Check the end play of each piston assembly. End play must not be more than 0.005" (0,127 mm) between the piston and the
Fig. 3-48
Bearing Inspection
This Dimension Must be Maintained on All Nine Shoes Within 0.001 Inch
Piston Inspectioi
Piston
Shoe Must Swivel Smoothly on Ball. End Play Must not Exceed 0.005 Inch. Shoe Faces Sides On Swash Plate Fig. 3-50
A-1850
Piston Dimensions
-3-1799 of 252
Fig. 3-49
Shoe
(5)
shoe (Fig. 3-50).
t-5040
B-501
2000 RTF Service Manual
Measure the thickness of each shoe (Fig. 3 — 51). All shoes must be within 0.001" (0,025 mm) of each other. (6)
OD (7) Check the shoe plate for cracks and deep scratches due to pin breakage.
B-4985
5037
Fig. 3-51 Piston Shoe
Fig. 3-52
inspectic
Spherical Washer Inspection
(8) Check the spherical washer for sharp edges, wear or scratches (Fig. 3-52).
length (Fig. 3 — 53) and must be straight.
4984
Fig. 3-53
Checking the Pins
Resle
(9) Check the pins for wear or damage. All pins must be the same
(1 0) Check the spring, washer and snap ring' in the cylinder block (Fig. 3 54). If the spring parts are damaged replace the block as a unit. DO NOT disassemble the
—
cylinder block. -4990
Fig. 3
NOTE:
— 54
Checking the Spring
If there is any damage to the rotating group, the complete unit must be replaced.
-)))-)))
(11) Check the yoke for wear or damage (Fig. 3—55).
B-4962
Fig. 3-55
Yoke Inspection
-3-18100 of 252
2000 RTF Service Manual
No. 2 Pump Housing
ÿ
"Yiitfsi
JS>
\
,.®
i*<*
- fc-*
Rotating Group
0
35=
wt'"-®
"
d-o- -ao_
lOo-
Rotating Group
t
No. 1 Pump Housing
J ©©ÿ
Manifold Block
*>®,
D-1614
Fig. 3-56
Hydrostatic Pump Assembly
3 — 6.4 Assembly of the Hydrostatic Pump (Fig. 3 — 56) (1) Use a press to install the bearing on the drive shaft and the bearing race into the hydrostatic pump housing. Push the bearing and race until each is against the shoulders on the shaft and the housing.
IMPORTANT
Resle
(P
Use a top grade grease or vaseline petroleum jelly to lubricate the seals, o-rings and the bearings. 4979
Fig. 3-57 (2) Install the drive shaft through the yoke and install the drive shaft and yoke together into the pump housing (Fig. 3 — 57).
NOTE:
Instating Shaft & Yokÿ
O
Make sure the long pintle shaft is on the correct side of the pump housing (See Fig.
o
3-56).
(3) Install the pintle bearings and the bearing races on each end of the yoke (Fig. 3 — 58).
Install the bearing spacer on the short pintle shaft (Fig. 3 — 59).
Revised Aug. 83 101 of 252
1-6841
;-5050
(4)
Fig. 3-58
Installing Race & Bearing
-3-19-
* Fig. 3 — 59
Installing Bearing Spacer
2000 RTF Service Manual
(5) Install a new o-ring in the groove (Fig. 3 — 60).
NOTE:
If new bearings and races were installed go to Step 12. If the same bearings and races are being used, follow with Step 6 below.
(6) Install the exact same shims that were removed (or new shims the same thickness) from pintle cover on the short pintle (Fig.
B-4960
B-4993 nstalling Shims
installing O-Ring
3-61).
(7) Install the four pintle cover bolts. Tighten the bolts to 1 70 -190 in. -lbs. (19 - 22 Nm) torque (Fig. 3-62).
(8) Install the bearing spacer on the pintle shaft (Fig. 3 — 63).
(9) Install a new o-ring in the groove (Fig. 3 — 64).
-5052
B-4974
* Fig. 3-63
Fig. 3-62 Tighten Bolts
Installing Bearing Spacer
(10) Install the same shims removed under the pintle cover and install the pintle cover/seal on the long pintle shaft (Fig. 3 — 65).
Resle
o, (11) Install four pintle cover bolts. Tighten the bolts to 1 70 - 190 in.-lbs. (19-22 Nm) torque (Fig. 3-66).
(12) If new bearings and races were used, follow Steps a thru h.
NOTE:
------
B-5003
8-5049
ig. 3 — 64
Fig. 3 — 65
Installing O-Ring
Shims are color-coded to thickness. Green 0.003" (0,076 mm) Blue - - - 0.005" (0,127 mm) 0.010" (0,254 mm) Brown
Installing Shims & Seal
o
(a) Install one 0.01 0" (0,254 mm) shim under the pintle cover and install the pintle cover on the short pintle.
(b)
(19
-
Install four pintle cover bolts. Tighten the bolts to 1 70 22 Nm) torque.
-
1 90 in. -lbs. -4980
(c)
Position the housing on the side so that the long pintle shaft is up.
Revised Aug. 83 102 of 252
-3-20-
ÿ'9- ÿ
Tighten Bolts
2000 RTF Service Manual
(d) Install the bearing spacer and turn the yoke while pushing on the spacer so that the bearing and spacers are in correct position (Fig. 3 — 67).
(e) Hold the spacer against the bearing race and measure the distance between the spacer and the surface of the housing. Measure in two different locations 1 80° apart (Fig. 3 — 68).
(f) Add the two dimensions and divide by 2 to get an average. Subtract the nominal preload of 0.008" (0,0203 mm), 0.007" to 0.009" (0,178 -0,229 mm) actual from the average. The remainder after subtracting is the thickness of the- shim needed to give the correct pre-load on the bearings. B-4964
Fig. 3-67
EXAMPLE
Seating the Bearing
(In Inches):
0.029 Measured distance between the spacer and the housing surface. at 180° from the first measurement. = 0.056
+ 0.027 Measured distance
0.056 Divided by 2 equals 0.028 Average 0.028 Minus 0.008 (Nominal Pre-Load) equals 0.020 0.020 Is the thickness of the shim needed.
NOTE:
If the thickness becomes more than 0.020" (0,508 mm) add another shim short pintle side and follow steps "d" thru "f" again. This is necessary to give the correct compression of the o-ring and prevent leakage at the seal.
Resle
to the
(g)
Install the pintle cover/seal on the long pintle shaft (Fig. 3 — 60).
(h) Install the four pintle cover bolts. Tighten the bolts to 170 - 190 in.-lbs. (19-22
Nm!
NOTE:
torque.
Use the same procedure to install the yoke and the bearings in the other
L
hydrostatic pump.
The yoke must have a small amount of resistance but must not move hard or with no resistance.
C-2272
Fig. 3
— 68
Checking the Pre-Load
-3-21103 of 252
2000 RTF Service Manual
NOTE:
If the shaft bearings, valve block, housing or the spacer were not installed new, use the same parts that were removed and go to step 14. If any new parts are used start with step 13.
( 1 3) Adjust the bearing pre-load on the housing.
(a)
Install the
thickest
bearing spacer over the shaft with the chamfer edge toward the shoulder on the shaft (Fig. 3-69).
I-4995
B-5004 Installing Spacer
Fig. 3-70
Installing the Housing
(b) Install the bearing on the shaft and against the spacer. The small end of the tapered bearing goes toward the manifold block.
(c) Install the housing on the manifold block without a gasket and the rotating group (Fig. 3 — 70). Turn the shaft while installing so the bearings are in the correct position.
(r% (Y I1, 1 £v\L rvÿfnl—— /A>
lÿdjyÿjn (°/x\
/
(e) Install the four (4) bolts in the four corners and tighten finger tight only. Tighten the bolts evenly so that the gap is as even as possible.
1
B-5000
Fig. 3-71 Installing the Shaft (f) Use a feeler gauge to check the gap (Fig. 3 — 72). A tapered feeler gauge is very good for this purpose. Measure the gap at four different corners. Add the four dimensions together and divide by 4 to get an average gap dimension.
EXAMPLE (In Inches): 0. 1 50 Measured thickness of the bearing spacer. -0.027 Average gap (from above) + 0.003 +0.001 necessary pre-load + 0.020 Compressed thickness of the gasket. = 0.146
+0.001 thickness of the bearing spacer needed to give 0.002 to 0.004 bearing pre-load.
Remove the four bolts and remove the housing from the manifold so that the correct spacer, gasket and internal parts can be installed.
B-4999
(g)
-3-22104 of 252
Fig. 3-72 Checking the
Gap
2000 RTF Service Manual
Resle
Temporarily install the vane pump shaft into the intermediate shaft (Fig. 3 — 71). This step is not needed on the rear pump. (d)
NOTE:
Lubricate all the moving parts before assembly.
(14) Install the pin retainer abour 1/4" (6,35 mm) below the surface with the opening away from the large spline (Fig. 3 — 73).
(1 5) Push the three (3) pins in the cylinder block until each pin hits the spring washer in the block (Fig. 3 — 74).
(1 6) Put the spherical washer on the top of the three pins (Fig. 3 — 75). Install the shoe plate and the pistons. Make sure you put the marked piston into the marked hole (Fig. 3 — 76). Make
B-501 7
Fig. 3-73
Installing Pin Retainer
sure all the pistons move freely in the cylinder bores.
(17) Hold the intermediate shaft horizontal and move the rotating group until the splines are in alignment.
(19) Install the tapered bearing with the small end toward the manifold block.
B-4972
B-497 1
Fig. 3-74
Fig. 3-75
Installing Pins
\I
1 fviASgMV
Installing Spherical Washer
*1 Resle
( 1 8) Install the correct spacer (use the original spacer if no new parts are used) on the intermediate shaft with the chamfer toward the shoulder on the shaft.
(20) Install the two roll pins and a new gasket.
ÿ ÿ (21) Put the assembled unit in a
clean area until final assembly.
3 — 6.5 Installing Pumps Manifold Block
to
Fig. 3
— 76
B-5002
installing Pistons
the
(1) Install the wafer plate locating pins in the manifold block.
(2) Install the wafer plate (For#1 housing). The wafer plate must be flat against the manifold block (Fig. 3-77).
Fig. 3 — 77
Installing Wafer Plates
-3-23105 of 252
2000 RTF Service Manual
NOTE:
The wafer plates for the front and rear pumps (Fig. 3 — 78) are not interchangeable. Use the correct wafer plate for each pump.
Cylinder
Rotation Cylinder
Rotation
Put the splined coupler on the drive shaft (Fig. 3 — 79). (3)
(4) Make sure the gasket and the alignment pins are in the correct location and install the housing on the manifold block,
Install the six (6) bolts and tighten to 23 - 26 ft. -lbs. (31 - 35
REAR PUMP
FRONT PUMP
-4977
(5)
Fig. 3-78
Correct Wafer Piate
Nm) torque.
(6) Turn the vane pump shaft in the intermediate shaft until it is against the shoulder. Then turn the vane pump shaft out to align the splines.
(7) Put the splined coupling over the splines on the intermediate shaft and the vane pump shaft.
(8)
Install the snap ring in the g oove on the vane pump shaft.
Resle
(9) Install the wafer piate (For #2 housing). The wafer plate must be flat against the manifold block.
( 1 0) Make sure the gasket and the alignment pins are in position and install the housing on the manifold block. Turn the vane pump shaft so that the splines are in alignment.
(11) Install the six (6) bolts and tighten to 23 - 26 ft. -lbs. (31 - 35 Nm) torque.
B-4994
Fig. 3-79
installing Coupler
(12) Install the large o-ring on the end of the # 2 housing and install the vane pump.
(13) Install the two (2) bolts to hold the vane pump and tighten to 54 - 66 ft. -lbs. (73 - 89 Nm) torque,
3 — 6.6 Hydrostatic Pump Installation ( 1 ) Install a chain on the hydrostatic pumps and position the pumps under the machine.
-3-24106 of 252
5638
Fig. 3-80
Installing the Hydrostatic Pump
2000 RTF Service Manual
(2)
Put
a
sling
around
the
operator cab on the machine and install a chain hoist (Fig. 3 — 80).
(3) Hook the chain hoist to the chain on the hydrostatic pump and lift the pumps into position.
(4) Carefully install the splined end of the shaft into the engine flywheel.
(5) Install the rear mounting bolts (Fig. 3 — 81) and tighten to 70 ft. -lbs. (95 Nm) torque. Put loctite on the threads.
(6) Install the rear axle and hydrostatic motor assembly into the machine (See Paragraph 4-5.3, Page 4-3).
Fig. 3-81
Installing Rear Mounting Bolts
(7) Install the left pump mounting bracket (Fig. 3 — 82, Item 1), install the bolts and tighten.
(8) Install the pintle arm, servo control cylinder and shock absorber assembly on the hydrostatic pumps.
(10) Install the pintle arms on the pintle shafts and tighten the bolts to 1 8 - 20 ft. -lbs. (24 - 27 Nm)
B-5588
Fig. 3-82 Installing Left Mounting Bracket
torque.
(11) Connect the linkage at the rod end of the servo control.
(12) Connect the linkage at the centering mechanism.
(13) Connect the ballstud at the front of the servo control cylinder linkage.
(14) Install the right side pump mounting bracket (Fig. 3 — 83, Item 1), install the bolts and tighten.
(15) Connect connections.
all the
electrical
B-5586
Fig. 3-83
Installing Right Mounting Bracket
-3-25107 of 252
2000 RTF Service Manual
Resle
(9) Install the upper bolt in the shock absorber and tighten.
Install the heat shields in the machine (Fig, 3 — 84).
(16)
(17) Connect all the hoses and tubelines and tighten. (1 8) Add fluid to the reservoir (See Specification for the correct fluid). (19) Install the fuel tank in the machine (See Paragraph 5 5.2, Page 5 — 3).
/
—
(20) Before you start the engine on the machine, see Paragraph 3 — 7.8 for the correct start-up procedure. (21) Adjust the servo control cylinder for neutral position (See Paragraph 3 — 3.1).
Rear of
Machine
C-2758
Fig. 3-84
Installing the Heat Shield and Screen
(22) Install the floorpanels and the floor mats (See Paragraph 5-3).
5 — 3.2, Page
(23) Lower the machine from the blocks.
3 — 6.7 Hydrostatic Pump Start-Up Procedure (1 )
Engage the parking brake.
(2)
Make sure all the hoses and tubelines are tight.
(3)
Check the reservoir. Add the correct fluid as needed.
(4)
Install the charge pressure gauge (See Paragraph 3 — 5.1).
Resle
(5) Loosen the outlet fitting at the hydraulic pump. Turn the engine with the starter until fluid comes from the fitting. Also watch the charge pressure gauge.
Tighten the fitting. (6) With the foot pedal in the neutral position, Start the engine and run at a slow RPM. The charge pump must immediately pick up fluid and fill the system. If there is no sign of a fill in 30 seconds, stop the engine and check for the cause. (7) After the system is full, at a slow rate move the foot pedal into forward position. Operate the system at a slow rate with no load until the system is at normal operating temperature.
(8)
Stop the engine. Check the reservoir. Add fluid as needed.
(9)
Check all the tubelines and hoses to make sure there are no leaks.
(10) Go back to step 21 of Installation of the Hydrostatic Pumps.
3-7 HYDROSTATIC MOTOR The hydrostatic motor is a fixed displacement piston type motor that provides power to move the machine.
NOTE:
In troubleshooting a pump-motor system, you must first find out which component is bad. A worn pump or motor will both cause the same problem. Therefore you must first run a pressure and flow check on the pump to make sure it is working properly.
-3-26108 of 252
2000 RTF Service Manual
3 — 7.1 Hydrostatic Motor Removal
To remove the hydrostatic motor from the machine, use the following procedure: (1)
Lower the vertical lift and
stop the engine.
(2) Lift and block the machine (See Section 1—2, Page 1 — 1 ). (3) Remove the fluid from the reservoir (See Paragraph 2 — 4.2, Page 2 — 4). (4) Remove the driveline from the machine (See Paragraph 2 — 4.1, Page 2 — 4).
Remove the floormat and floorpanels (See Paragraph 5-3.1, Page 5-1). (5)
B-5591
Fig. 3-85
Installing the Transmission Jack
Fig. 3-86
Removing Hydrostatic Motor Bolts
(6) Disconnect the brake cable from the brake assembly (See Paragraph 4 — 8.3, Page 4 — 23).
(7) Remove the four high pressure hoses from the manifold
block. (8) Remove the case drain hose and install jack under the motor (Fig. 3-85).
(9)
Remove the four bolts which hold the motor to the axle housing
(10) Turn the motor so that the brake cable mounting bracket is in a down position.
Resle
(Fig. 3-86).
(11) Lower the jack and remove the hydrostatic motor.
3 — 7.2 Hydrostatic Motor Disassembly
The tools listed will be needed to do the following procedure: MEL - 1 1 98
Bearing Press Tool
IMPORTANT NOTE:
Always use caps and plugs in openings or ports to keep debris out of the hydrostatic system.
Clean the outside of the hydrostatic motor before disassembly. Keep all the parts of the motor clean.
-3-27109 of 252
2000 RTF Service Manual
(1) Remove the parking brake assembly from the motor (See Paragraph 4 — 8.5, Page 4 — 23).
(2) Remove the nut from the gear on the drive end of the motor.
(3) Using a puller, remove the gear from the motor (Fig. 3 — 87).
Fig. 3-87
NOTE:
B-561 1
B-56 1 0
Fig. 3-88
Removing Gear
Removing the Bolts
This is a tapered fit on the gear and shaft. Be careful.
(4) Remove the bolts at the manifold block on the motor (Fig.
SinU,
ÿ
3-88).
/
Remove the manifold block from the motor (Fig. 3 — 89). (5)
JV:|
3§cP i r
Fig. 3 — 89
B-561 3
B-561 2
Removing Manifold Slock
Fig. 3-90
Removing Back Plate
Fig. 3-92
Removing Piston Assembly
Remove the bolts at the back plate (Fig. 3 — 90). (6)
(7)
Remove the back plate and
Resle
connector plate from the housing (Fig. 3-91).
(8) Remove two pistons from the rotating group.
6-5614
(9) Remove the piston assembly from the housing (Fig. 3 — 92).
Fig. 3-91
Removing Connector Plate
X ( 1 0) Remove the three bolts at the
drive end of the housing (Fig. 3-93).
(11) Remove the shaft and rotating group from the housing.
. . -t-\ >$ (k.4) ÿ
Ssc
(12) Remove the snap ring at the bearing (Fig. 3 — 94).
'
-
ÿ
/ /'
A/-
8-5616
Fig. 3-93
Removing Drive End Bolts
B-561 7
Fig. 3-94
Removing Bearing Snap Ring
2000 RTF
-3-28110 of 252
Service Manual
(13) To remove the bearing from the shaft, use the following procedure:
Install a guide stud (Fig. 3 — 95, Item 1) into the camplate. (a)
(b) Install the shaft and rotating group back into the housing (Fig. 3 — 95) and make sure the holes are in correct alignment. B-56 1
Fig. 3-95
Cam Plate & Rotating Group Assembly
(c) Install the three bolts and tighten,
-_ _ _ _
3-96).
NOTE:
Make sure the motor housing has a good support and support the shaft and rotating group so they do not drop.
_
Fig. 3-96
(e)
.,
_
B 5619
___
Remove the three bolts from the housing.
B-5620
Remove the
Removing Cam Plate
camplate
(Fig. 3-97).
1 A/
Remove the bearing from the housing (Fig. 3 — 98). (g)
(14) Remove the snap ring from the rotating group (Fig. 3 — 99).
—
-
-
\ /
/•if
]\ kL/
(c
B-5622
B-562 1
Fig. 3-98
Removing Bearing
-3-29111 of 252
x.
f I 1
—
Removing the Shaft
Fig. 3-97
(f)
•'//
Resle
(d) Put the motor in a hydraulic press and remove the shaft and rotating group from the housing (Fig.
Fig. 3-99
Removing Snap Ring
2000 RTF Service Manual
(15) Remove the piston assembly (Fig. 3-100).
(1 6) Install the shaft and piston in the vise.
NOTE:
The special tool (MEL-1198) may be used to support the assembly.
M B-5623
Fig. 3-100
Removing the Pistons
(17) Using a spider (Fig. 3 — 101, Item 1), push down on the spider
B- 56 24
pivot and spring.
Fig, 3-101
Installing Spider Pivot
Fig. 3-104
Removing Retainer Ring
Fig. 3-105
Removing Snap Ring Seal
( 1 8) Remove the retainer ring (Fig. 3-102).
(1 9) Remove the inner race, spider
pivot and spring from the shaft (Fig. 3-103).
Fig. 3-102
Removing Retainer Ring
Resle
(20) Remove the retainer ring (Fig. 3 — 104) and remove the piston block from the shaft.
(21) Remove the snap ring (Fig. 3 — 105) from the housing and remove the seal from the housing.
B-5626
Fig. 3-103
Removing Spider Pivot & Spring
3 — 7.3 Inspection of the Hydrostatic Motor
Inspect the hydrostatic motor for wear or damage as follows:
(1)
Clean all the parts in the correct and clean solvent.
(2) Check the needle bearings. If the needle bearings are free of excessive wear or damage and stay in the bearing cage, do not replace the bearings. B-5629
(3)
Check the inner race for wear or damage.
-3-30112 of 252
2000 RTF Service Manual
(4) Check the spiders and spider pivots. The conciai surface must be free of wear or damage.
(5) Check the pistons. The sides of the pistons must be free of wear or damage. The shoes must fit tight. The face of the shoe must be flat and free of wear or damage.
NOTE:
DO NOT lap the piston shoes.
(6) Check the piston block (Fig. 3— 1 06), the bore and keyway must be free of wear or damage.
ÿ5628
Fig. 3-106 (7)
NOTE:
Piston Block
Check the connector plates (Fig. 3 — 107) for excessive wear or damage,
DO NOT lap the connector plates.
(8) Check the back plate surface (Fig. 3 — 107) for damage, metal build-up, scoring, galling or scratches.
NOTE: DO NOT lap the back plate surface.
(9) Inspect the shaft for wear or damage at the threaded ends. Inspect the keyway and key wear.
-5630
Fig. 3-107
Connector Plate
3 — 7.4 Assembling the Hydrostatic Motor
MEL - 1 1 98
Bearing Press Tool
IMPORTANT NOTE:
Keep all the hydrostatic parts clean. Dirt in the system will cause damage in a very short time.
B-5627
Fig. 3-108
Installing Retainer Ring
Always use a NEW seal kit when assembling the motor. Lubricate all the parts with
(1)
Resle
The tools listed will be needed to do the following procedure:
clean fluid.
Install the shaft in the vise.
NOTE: The special tool (MEL - 1 198) can be used to support the shaft.
(2)
Install the key in the shaft and install the piston block on the shaft.
(3)
Install the retainer ring on the shaft (Fig. 3—108). -3-31-
113 of 252
2000 RTF Service Manual
(4) Install the spring and spider pivot on the shaft.
1ÿ (5) Using a spider plate (Fig. 3-109), push down and install the retainer ring (Fig. 3—110).
Fig. 3 — 110
(6) Install the piston assembly and camplate (Fig. 3—1 1 1).
(7)
Installing Retainer Plug
m. B-5624 Fig. 3-109
Installing Spider
Install the snap ring for the
bearing.
B-5633
B-5632
Fig. 3-111 Installing Piston Assembly
Fig. 3-112
Installing the Tool
(9) Put the shaft and rotating group in the hydraulic press (Fig. 3-113).
(10) Position the special tool over the bearing (Fig. 3—1 13).
I
W
(11) Push the bearing into position (Fig. 3—114). Make sure the bearing is centered in the camplate.
Installing the Bearing
-3-32114 of 252
--3
,
-
B- 5635
3 bo34
Fig. 3-113
J
Fig. 3-114
Checking Snap Ring Clearance
2000 RTF Service Manual
Resle
(8) Install the bearing on the end of the shaft (Fig. 3 — 1 12).
IMPORTANT Push down on the bearing just far enough until the snap ring can be installed (Fig. 3 115). The notch in the special tool will show the snap ring groove. DO NOT go past the snap ring groove.
—
n B-5636
Fig. 3-115
Installing the Snap Ring
B-5626
Fig. 3-116
Installing Spide Pivot & Spr ing
(12) Install the snap ring on the shaft (Fig. 3—1 16).
(1 3) Install the spring, spider pivot and inner race (Fig. 3— 1 1 7).
(14) Using a spider plate push down on the spider pivot (Fig.
3-113).
B-561
Fig. 3-117
Installing Guide Stud
(15) Install the retainer ring (Fig. 3-110).
Install a guide stud in the camplate (Fig. 3—1 17) and install the rotating group and shaft assembly into the housing. Make sure the holes are in correct alignment (Fig. 3— 1 18).
Resle
(16)
4h
Remove the guide stud. Install new o-rings on the three bolts and tighten to 8-10 ft. -lbs.
J- 5616
B-5637
(17)
Fig. 3
Fig. 3-118 Hole Alignment
— 119
Installing Drive End Bolts
(11-14 Nm) torque (Fig. 3-119).
( 1 8) Lubricate the pistons and install into the piston block (Fig. 3-1 20).
(1 9) Install
the last two. pistons.
B-561 5
(20) Install the
connector plate and back plate (Fig. 3— 121).
ig. 3-120 Installing Piston Assembly
-3-33115 of 252
Fig. 3-121
Installing Connector Plate
2000 RTF Service Manual
(21) Install the back plate bolts and tighten to 40 - 45 ft. -lbs. (54 -61 Nm) torque (Fig. 3—122).
NOTE:
See Paragraph 3 — 8.5 Manifold Block Repair.
for B-561 3
Fig. 3
— 122
Installing Back Plate Bolts
(22) Install the manifold block and tighten the bolts (Fig. 3—123).
B-561 2
Fig. 3-123
Installing Manifold Block
Resle
(23) Install the seal using the special tool, in the housing (Fig. 3 — 124). Press the seal into position until the flat edges of the groove on the special tool is even with the edge of the end plate.
(24) Install the snap ring. B-563 1
Fig. 3-124
Installing the Seal
(2 5) Install the drive gear at the drive end of the motor and tighten the nut to 250 - 255 ft. -lbs. (339 -346 Nm) torque.
(26) Install the brake assembly on the hydrostatic motor (See Paragraph 4-8.6, Page 4-24).
-3-34116 of 252
2000 RTF Service Manual
3—7.5 Manifold Block Disassembly (Fig. 3-125)
1.
2. 3.
Port Block Case Drain Fitting Spring Retainer
4. 5. 6.
Spring Poppet
Shuttle Plug
7. 8. 9-
Spring Spool Relief Valve
1 0. 1 1.
Tow Valve Hose Fitting
12. Shim
(1)
From the block ( 1) remove the stroked charge relief valve fitting (2).
(2) Use an alien wrench to remove the stroke charge relief valve spring retainer (3). (3) Remove the spring (4) and poppet (5).
AWARNING Make sure to use an alien wrench which is designed for impact wrench operation. Use it in the following step.
Front View Fig. 3-125
Side View
C-2694
Manifold Block for the Hydrostatic Motor
(5)
Remove the spring (7) and the shuttle valve (8).
(6)
Remove the two drive relief valve plugs (9) and springs.
(7)
Remove the two drive relief valves (9).
Resle
Use an air wrench with the alien wrench and remove the two shuttle plugs (6). (4)
3—7.6 Manifold Block Assembly (Fig. 3—125) (1)
install the two drive relief valves (9) in the manifold block (1).
(2) Apply loctite to the high pressure relief valve plugs. Install the springs and tighten the plugs.
3
(3)
Install the shuttle valve (8) and springs (7).
(4)
Use an air wrench to tighten the plugs (6).
(5)
Install the poppet (5) and spring (4).
(6)
Use an alien wrench to tighten the retainer (3) and install the fitting.
(7)
Install the new seal in the center hole of the manifold block.
— 7.7 Hydrostatic Motor installation (1)
Put a bead of silicone sealer around the mounting flange of the hydrostatic
motor. (2) Put the motor on a jack. Turn the motor so that the brake cable mounting bracket is in down position.
2000 RTF -3-35-
117 of 252
Service Manual
(3) Using the jack, lift the motor into position. Turn the motor to make alignment of the four mounting holes. (4)
Install the four bolts and tighten to 70 ft. -lbs. (95 Nm) torque.
(5)
Connect the case drain hose to the manifold block.
(6)
Connect the four high pressure hoses to the manifold block.
(7) Connect the brake cable and adjust it (See Paragraph 4 — 8.4, Page 4-21). (8) Before the engine is started, see paragraph 3 — 8.3 for the correct start-up procedure. (9) Install the floorpanels and the floormat (See Paragraph 5-3).
5 — 3.2, Page
3 — 7.8 Hydrostatic Motor Start-Up (1 ) Make sure all the hydraulic hoses and the tubelines are tight. (2)
Add fluid to the reservoir and make sure it is at the correct level.
AWARNING (3)
Make sure the jackstands are in the correct position to prevent the machine
from falling
and causing personal
injury.
Connect a gauge to the charge pressure port (See Paragraph 3 — 5).
(4) Loosen the fitting at the outlet of the hydraulic pump. Turn the engine with starter until fluid flows from the fitting. Tighten the fitting. (5) Engage the parking brake and make sure the foot pedal is in the neutral position.
(6) Start the engine and run at low RPM. The hydraulic pump must immediately pick up fluid and fill the system, if there is no sign of a fill in 30 seconds, stop the engine and check for the cause.
Resle
(7) After the system shows signs of fill, move the foot pedal into forward position a small amount. Continue to operate the system at a slow RPM, with no load on the motor, until the system has a normal operation.
(8) Stop the engine, check the fluid level in the reservoir. Add the correct fluid as needed. (9)
Check all hoses and tubelines for leaks.
(10) Remove the jackstands from under the machine.
NOTE: The filter must be changed in 3 to 5 hours of operation after the hydrostatic system has been repaired or opened. After the first filter change, go back to the normal maintenance schedule. 3 — 7.9 Tow Valve A machine that will not start or has hydrostatic problems can be moved for a short distance (25 feet) at a slow speed. The tow valve is installed in the hydrostatic motor mainfold block (Fig. 3— 1 26, Item 1 ).
IMPORTANT
DO NOT move the machine at more than 2 mph or for a distance of more than 25 feet.
To open the tow valve, turn the shaft 1/ 4 turn in either direction, move the machine and close the valve. NOTE: Make sure to close the tow valve. The machine will not operate with this valve in the open position.
-3-36118 of 252
\
Motor
2.
Block
\ Manifold
Drive Shaft
_ !L4r -4087
Fig. 3-126
Tow Valve
2000 RTF Service Manual
DRIVE SYSTEM Paragraph Number DESCRIPTION DIFFERENTIAL OIL LEVEL DISASSEMBLING AND ASSEMBLING AXLES DRIVE SHAFT FRONT AXLE LUBRICATING THE U-JOINTS PARKING BRAKE REAR AXLE
Page
Number
4-1 4-2
4-1
4-7 4-4 4-6 4-3 4-8 4-5
4-4 4-1 4-3 4-1 4-22 4-2
4-1
Resle
DRIVE SYSTEM
A WARNING 119 of 252
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
2000 RTF Service Manual
Resle 120 of 252
4 DRIVE SYSTEM
4-1 DESCRIPTION
Final drive of the Bobcat Forklift is the front and rear axles. The hydrostatic motor is connected to the rear axle through a gearbox.
The drive shaft connects the 2 axles together. There is a U-joint at each end of the drive shaft (Fig. 4— 1 ). 8-3874
Fig. 4 — 1 u-Joint The rear axle has a limited slip differential and the front axle has a standard differential.
4-2 DIFFERENTIAL OIL LEVEL
See paragraph 1—15, page 1—17.
4-3 LUBRICATING THE U-JOINTS
Resle
Lubricate the U-joints with a good quality lithium based multi-purpose grease every 100 hours (See the Parts Manual for the recommended grease).
4-4 DRIVE SHAFT
4
— 4.1 Removing the Drive Shaft
Remove the drive shaft as follows:
(1) Put the machine on a level surface. Lower the vertical lift and stop the engine.
(2) Remove four (4) nuts from the U-joints at both ends of the drive shaft (Fig. 4-2),
NOTE:
Be careful not to lose the bearing caps when removing the drive shaft.
Remove the four (4) U-bolts, lower the drive shaft and remove the drive shaft from the machine.
B-5666
(3)
-4-1121 of 252
Fig. 4-2
Removing U-Joints
2000 RTF Service Manual
4 — 4.2 Installing the Drive Shaft
Install the drive shaft as follows:
NOTE:
When installing the drive shaft, make sure the bearing cups and yokes are in alignment with each other from end to end (Fig. 4 3).
—
(1)
Put the drive shaft in place.
(2)
Install four (4) U-bolts and four (4) nuts (Fig. 4 — 2).
(3)
Tighten nuts to 25 to 28 ft. -lbs. (34 to 38 Nm) torque.
4-5 REAR AXLE 4 — 5.1 Description
Resle
The rear axle is a heavy-duty axle. A limited slip differential is installed in the rear axle.
4—5.2 Removing the Rear Axle
Remove the rear axle as follows:
(1) Lower the vertical lift and stop the engine. Lift and block the machine (See Paragraph 1—2, Page 1—1 for correct procedure).
B-5735
Fig. 4-3
U-Joint Alignment
Install the frame lock.
NOTE:
Raise the rear of the machine about 22" from the floor so that the rear axle and hydrostatic motor can be removed as an assembly.
(2)
Remove the drive shaft (See Paragraph 4 — 4.1).
(3) Remove the hydrostatic motor hoses. Remove the cable at the parking brake.
Remove the eight (8) lugs which fasten each rear wheel. Remove the wheels (Fig. 4 — 4).
__
\ "
I
\
.. s
ÿ
122 of 252
I
ÿr-r
B-5667
(4)
-4 — 2-
i1
Fig. 4-4
Removing The Wheels
2000 RTF Service Manual
(5)
Put a floor jack under the center of the rear axle (Fig. 4—5).
(6) Remove the eight (8) bolts which fasten the rear axle to the frame. There are four (4) bolts on each side of the machine (Fig. 4 — 6). (7)
NOTE:
Lower the floor jack and remove the rear axle and hydrostatic motor. Do not remove the jackstands until the axle is installed.
4 — 5.3 Installing the Rear Axle
Install the rear axles and drive motor as follows: (1 )
Put the center of the rear axle on a floor jack.
8-5668
(2) Raise the axle into place with the floor jack. Line up the holes for the eight (8) bolts which fasten the axle to the frame (Fig. 4 — 5).
Fig. 4-5
(3) Fasten the axle to the frame with eight (8) bolts (Fig. 4 — 6). Put Loctite on the threads. Tighten the bolt to 245 ft. -lbs. (332 Nm) torque. (4)
Install the drive shaft (See Paragraph 4 — 4.2).
(5)
Remove the jackstands from the machine.
_ JJ
I
ÿ
U-
4-6 FRONT AXLE
Jacking the Rear Axie
4 — 6.1 Description The front axle is a heavy-duty axle. A standard differential is installed in the front axle.
'
.
ÿ:!(=>
l(>Avvb _
4—6.2 Removing the Front Axie Fig. 4-6
B-5669
Removing Rear Axle Bolts
Lower the vertical lift and stop the engine. Lift and block the machine (See Paragraph 1 —2, Page 1 — 1 for correct procedure). Install the frame lock. (1 )
(2) Install the frame lock. Remove the vertical mast (See Paragraph 5A — 2, Page 5A— 1 ).
Remove the drive shaft (See Paragraph 4 — 4.1).
Resle
(3)
Remove the eight (8) lugs which fasten each front wheel and the eight (8) lugs which fasten the rear left wheel (Fig. 4 — 4).
(4)
(5)
Put a floor jack under the center of the front axle (Fig, 4 — 7).
(6)
Remove the six (6) bolts which fasten the axle
(7)
Lower the floor jack and remove the front axle.
NOTE:
to
the frame (Fig. 4 — 8). 8-5670
Do not remove the jackstands until the axle is installed.
Fig. 4-7
Jacking the Front Axle
4 — 6.3 Installing the Front Axle (1 )
Place the center of the front axle on a floor jack.
(2) Raise the axle into place with the floor jack. Line up the holes for the six (6) bolts which fasten the axle to the frame (Fig. 4 — 6). (3) Fasten the axle to the frame with six (6) bolts (Fig. 4 — 8). Tighten to 245 ft. -lbs. (332 Nm) torque. (4)
Install the drive shaft (See Paragraph 4 — 4.2).
(5)
Install the vertical mast (See Paragraph 5A — 3, Page 5A — 2).
(6)
Install the wheels and tighten the nuts.
(7)
Remove the jackstands from the machine.
Fig. 4-8
-4-3123 of 252
ÿ
Removing Front Axle Bolts
2000 RTF Service Manual
4-7
AND
DISASSEMBLING
ASSEMBLING AXLES 4—7,1 Removing Hubs
The tools listed will be needed to do the following procedure:
MEL-1 145 — Locknut Socket MEL-1 1 66 — Driver Disc Handle MEL-1 1 67 - Driver Disc MEL-1 168 — Driver Disc MEL-1 172 - Special Disc
B-4794
B-4791
Fig. 4-9
Fig. 4-10
Removing Nuts
Removing Cone Washers
NOTE: All four (4) hubs are the same. Use the same procedure for each hub.
Remove hubs as follows:
(1) Remove six (6) nuts and six (6) cone washers from the axle housing (Fig. 4 — 9 and 4-10).
NOTE:
You may need to hit the axle flange in the center to loosen the cone washers (Fig.
B-4795
B-5079
Fig. 4-11
Fig. 4-12
Loosen Cone Washers
Removing Axle
4-11).
When the axle is removed, lubricant will come out of the hub.
Resle
NOTE:
(2) Hold the metal gasket against the hub and remove the axle from the housing (Fig. 4—12).
NOTE: The metal gasket can be used again if it is not damaged.
B-506 1
B-5058
Fig. 4-13
Removing Outer Bearing Locknut
Fig. 4-14
Removing Locking Ring
(3) Using the locknut socket, remove the outer bearing locknut (Fig. 4-13).
(4) Remove the locking ring (Fig. 4-14).
(5) Remove the bearing adjusting nut (Fig. 4—15).
(6)
Remove the outer
(Fig. 4-16).
Fig. 4-15
Locking Ring and Adjusting Nut
-4-4124 of 252
B-4796
B-5062
bearing
Fig. 4-16
Removing Outer Bearing
2000 RTF Service Manual
(7)
Remove the hub from the axle
housing (Fig. 4—17).
& Use the correct driver disc and handle to push the inner (8)
bearing, seal and back-up washer the hub (Fig. 4—18).
out of
Use the correct driver disc and handle to remove the outer bearing race (Fig. 4—19).
B-4780
(9)
Fig. 4-17
iSr 11
!
Fig. 4-18
Removing Axle Hub
B-4800
Removing Inner Seal & Washer
(10) Use the special disc and handle to remove the inner bearing race (Fig. 4 — 20).
4 — 7.2 Installing Hubs The tools listed will be needed to do the following procedure:
B-4806
Fig. 4-19
Removing Outer Bearing Race
N.
v*
i
NOTE:
* I
•
.» r! . •
--
J
All four (4) hubs are the same. Use the same procedure for each hub.
B-5064
Fig. 4-20
(1) Use the correct driver disc and handle to install the inner bearing race (Fig. 4 — 21).
Resle
MEL-1 1 66 — Driver Disc MEL-1 1 69 — Driver Disc MEL-1 1 70 — Driver Disc MEL-1 171 — Driver Disc
Remove Inner Bearing Race
J H
i
Use the correct driver disc and handle to install the outer bearing race (Fig. 4 — 22). (2)
1
•
(3) Put bearing.
grease
on
the
-U
1
f>-
inner
'
VVr NOTE:
The seal has a spring on the inside of the rubber; the spring goes into the hub first.
B-5063
B-5066
Fig. 4-21
Install Inner Race
-4 125 of 252
I
— 5-
Fig. 4-22
Install Outer Race
2000 RTF Service Manual
(4) Install the inner bearing, seal and back-up washer into the hub (Fig. 4-23).
.30" (7,62 mm)
_
(5) Use a press, the correct driver disc and handle to push the seal and washer into the hub (Fig. 4 — 23). Install the back-up washer into the hub until it is 0.300 (7,62 mm) from the end of the hub (Fig.
V
v
v
4-24). B-5080
Fig. 4
Install the hub assembly on the axle housing (Fig. 4 — 25). (6)
— 24
Depth of Back-up Washer
B-5065 B-5067
Put bearing.
(7)
(8)
NOTE:
(9)
grease
on
the
outer
Fig. 4-23
Installing Inner Seal & Washer
Install the outer bearing on the hub (Fig. 4 — 26).
The adjusting nut has a tab that goes to the outside end of the axle housing. I-4780
Install the bearing adjusting nut on the axle housing (Fig. 4 — 27). Fig. 4-25
Installing Hub Assembly
(10) Tighten the adjusting nut to 50 ft. -lbs. (68 Nm) torque.
Resle
(1 1) Loosen the nut and tighten it again to 35 ft. -lbs. (48 Nm) torque while turning the hub.
(1 2) Install the locking ring so that the tab on the nut (Fig. 4 — 28, Item 1 ) is in alignment with a hole in the locking ring (Fig. 4 — 28, Item 2). You may need to loosen the adjusting nut (1/4 turn maximum).
(1 3) Install the lockout on the axle housing and tighten it to 50 ft. -lbs. (68 Nm)
torque.
B-4796
Fig. 4-26
Installing Outer Bearing
(14) Clean the surface of the hub
and install the metal gasket over the studs.
(15) Install the housing.
axle
into
the
(16) Install six (6) cone washers and nuts. Tighten the nuts to 100 ft. -lbs. (136 Nm) torque.
(17) Add lubricant to the differential housing until it is at the
correct level.
126 of 252
i-5062
I-4798
Fig. 4-27
Installing Adjusting Nut
-4-6-
Fig. 4-28
Aligning Locking Ring
2000 RTF Service Manual
4 — 7.3 Removing Assembly
the
Differential
The tool listed will be needed to do the following procedure:
MEL-1 1 42 - Tool Kit
NOTE:
The illustrations for this procedure show the rear differential assembly (with limited slip differential). The procedure for removing the front differential assembly is the same.
B-4784
B-4788
Fig. 4-29
Fig. 4-30
Removing Cover
Identification Tags
Remove differential as follows:
( 1)
NOTE:
Remove ten (10) bolts and remove the differential cover (Fig. 4—29).
There is no gasket under the cover. Silicone sealant is used
to
seal the
cover. B-4791
(2)
You will find two metal tags which are held with two of the cover bolts
Fig. 4-31
Removing Nuts
(Fig. 4-30).
Resle
(a) The gear ratio tag is located at the bottom left hand side or the left side of the cover. This tag gives the tooth combination of the ring and pinion gears, and also the total gear ratio. (b) All rear axles have limited slip differential and have a special tag which specifies the use of special lubricant. This tag is located at the bottom right hand side of the cover.
(3)
Remove the lubricant from the housing.
B-4794
(4)
Clean the area of the differential housing and the cover to remove the silicone sealant.
Fig. 4-32
Removing Cone Washers
(5) Remove 1 2 nuts and 1 2 cone washers (six nuts and six washers on each axle) which hold the axle flange to the hub (Figs. 4 — 31 and 4 32).
—
(6) Pull the axles out until the splines are disengaged from the differential assembly.
NOTE:
The bearing caps and the differential housing have letters which are either in a vertical or horizontal position (Fig. 4 — 33). These letters must correspond when installing the bearing caps. 1-4814
(7)
Remove four (4) bolts and remove both bearing caps (Fig. 4 — 33).
-4-7127 of 252
Fig. 4-33
Removing Bearing Caps
2000 RTF Service Manual
(8) Install spreader tool on the housing (Fig. 4 — 34). Install two tabs and bolts as shown (Fig. 4— 34, Item 1 ).
Install a dial indicator on the housing (Fig. 4 — 34) so that the base of the indicator is on one side of the opening in the housing and the top of the dial is on the other side of the opening. (9)
(10) Set the dial indicator to zero CO").
IMPORTANT
B-5068
Fig. 4-34
installing Spreader Too!
Do not spread the differential housing more than .015 inches (0,38 mm).
(11) Turn the spreader bolt until the dial indicator shows 0.015"
(0,38 mm). (12) Use two prybars to remove the differential assembly from the housing (Fig. 4 — 35, Item 1).
Resle
(13) Remove the spreader tool from the differential housing. (14) Put tags on the bearings for identification of the bearings and races (ring gear side or opposite B-5069
side).
4 — 7.4 Removing the Ring Gear
Fig. 4-35
Removing Differential Assembly
NOTE: The illustrations for this procedure show the rear differential assembly (with limited slip differential). The procedure for removing the ring gear from the differential assembly is the same for both axles. Use the following procedure to remove the ring gear:
1,
2. 3. 4. 5. 6.
Step Plate Bearing Puller Tapered End Sleeve Adjusting Sleevf Tapered Bolt
The tool listed will be needed to do the following procedure: MEL-1145 — Bearing Remover (1 )
Put an axle in a vise to support the differential assembly.
(2) Use the bearing remover (Tool #MEL-1 145) to remove the bearing from the differential assembly (Fig. 4 — 36).
(3)
Use the bearing remover as follows: (a) If necessary, use the step plate (Fig. 4 — 36, Item 1 and Fig. 4 — 37) on the end of the shaft or hub. Shafts which have a pilot hole in the end do not need the step plate. (b) Put the bearing puller (Fig. 4 — 36, Item top of the rollers of the bearing.
128 of 252
B-5024
2 and Fig. 4 — 38, Item 2) on Fig. 4
-4-8-
— 36
Bearing Roller Tool
2000 RTF Service Manual
(c) Turn the tapered bolt (Fig. 4 38, Item 3) "in" until the tapered end just touches the center of the step plate (or the end of the shaft).
1. 2. 3. 4. 5.
—
Step Plate Bearing Puller Tapered End Adjusting Sleeve Tapered Bolt
(d) Install the sleeve halves (Fig. 4 — 39, Item 1) so that the groove fits over the shoulder of the adjusting sleeve and so that the bottom of the sleeve halves is under the bearing cage. (e) Hold the sleeve halves tight against the bearing and turn the adjusting sleeve (Fig. 4 39, Item 2 and Fig. 4 — 40,
—
Item 1) counterclockwise with your hand until it is tight. (f) Turn the tapered bolt (Fig. 4 — 40, Item 2) clockwise with a wrench to remove the bearing.
i-5022
8-501 3
Fig. 4-37
Fig. 4 — 38
instaliing Step Plate
Installing Bearing Puller
1. Adjusting Sleeve 2. Tapered Bolt
Put the differential on the axle with the teeth facing down. (4)
Put a soft material on the vise the ring gear from breaking if it falls when the bolts are removed from the differential (5)
to
protect
assembly (Fig. 4 — 41).
Remove 1 2 bolts from the ring gear (Fig. 4 — 41) and hit the ring gear with a soft hammer to remove it from the differential assembly (Fig. 4 — 42). (7)
Remove
the
differential
assembly and ring gear from the
Fig. 4-39
NOTE:
NOTE:
The ring gearand the pinion are a set. The number on the ring gear must be the same as that on
I-5035
1-5030
axle. Installing Sieeve Halves
Fig. 4-40
Resle
(6)
Removing Bearing
end of the pinion gear (Fig. 4 — 43).
Clark recommends that whenever the ring gear bolts are removed, you install new bolts.
4 — 7.5 Installing the Ring Gear
Install the ring gear as follows: (1) Install the ring gear on the differential assembly. Be sure that the ring gear is tight against the flange. Install 12 bolts and tighten them with your hands only. (2)
Putthedifferentialassemblyon the splines of the axle shaft again.
(3)
Tighten the 1 2 bolts evenly to 1 10 ft. -lbs. (149 Nm) torque (Fig. 4-41 ).
Fig. 4 — 41
Removing the Ring Gear Bolts
-4-9129 of 252
-5036
B-5036
Fig. 4 — 42
Removing the Ring Gear
2000 RTF Service Manual
4—7.6 Removing Clutch Plates NOTE:
Only the rear axle has clutch plates (limited slip differen¬ tial). This procedure is for the rear axle only.
Marks
Remove the clutch plates as follows: Put an axle in the vise and put the differential assembly on the splines of the shaft (Fig. 4 — 44).
B-5057
i-4856
(1)
Fig. 4
— 43
Ring Gear and Pinion Numbers
Fig. 4 — 44
Removing Differential Cap
(2) Put marks on the halves of the carrier so that the differential will be assembled correctly (Fig. 4 — 44). (3) Put marks on the cross shafts and on the carrier so that the cross shafts will be installed correctly (Fig. 4 — 44). (4)
NOTE:
Remove eight bolts from the differential cap (Fig. 4 — 44).
Cone Washer
You may need to hit the center of the differential cap to loosen the cone washers. I-5060
(5)
Remove the cone washers and remove the differential cap (Fig. 4 — 45).
Fig. 4 — 45
(6) Disassemble the clutch assembly and keep all of the plates and discs in exactly the same order as removed (Fig. 4 — 46).
Removing Differential Cap
Carrier Gear
Resle
4.
(7) Inspect the plates, discs, clutch rings, side gears, pinion gears and cross shaft for wear or damage.
(8) If any one of the plates or discs on either side has damage, replace all of the plates and discs on both sides (Fig. 4 — 47). Replace sets of clutch rings if one has damage,
B-4810
Fig. 4 — 46
Differential Assembly
(9) If one of the side gears or one of the pinion mate gears is damaged, replace the complete set. (10) If the cams of the pinion mate shafts are worn, install both new shafts (Fig. 4-48).
NOTE:
The pinion mate shafts are not fastened to the differential housing like a conventional differential.
(1 1) The ends of the pinion mate shafts have a "V" shape. The carrier case halves also have a "V" shape. If either half of the carrier case has wear at the "V", both halves of the carrier must be replaced (Fig. 4 — 48).
-4-10130 of 252
B-5010
Fig. 4-47
Inspect Plates and Discs
2000 RTF Service Manual
4 — 7.7 Installing Clutch Plates Install clutch plates as follows:
Inspect For Wear
(1)
Put limited slip lubricant (GM PartNo. 1 052358) on the surfaces of the plates and discs (Fig. 4 — 49). (2) There are five (5) plates and discs. Two (2) are concave (Fig. 4 — 46, Item 1 ). Align the tabs of the plates and install the concave plate first so that the raised center part (concave) of the plate is toward the center of the carrier. Install concave disc in the same manner. The other three (3) plates and discs are flat and must be installed in the same order as removed (Fig, 4 — 46) ,
Install the differential gear ring on top of the plates. (3)
(4)
B-5055
Fig. 4-49
Limited Siip Lubricant
i-5056
Fig. 4-48
Pinion Mate Shaft
Install the differential side gear into the center of the discs. Rotate the gear the splines.
to align
(5)
Repeat steps 2, 3 and 4 to assemble the other half of the carrier.
(6)
Put grease on all of the gears before assembly.
Align the marks on the pinion shafts and on the carrier, then install the pinion mate shafts and pinion mate gears into the carrier (Fig. 4 — 46, Item 4).
i-5054
(7)
Fig. 4-50
Removing Nut from Pinion
(8) Align the marks on the carrier halves then assemble the two halves of the carrier and install eight (8) bolts. Tighten the bolts with your hand only. (9)
Put an axle in the vise with the splines up.
Resle
(1 0) Put the differential assembly on the splines of the axle and tighten the eight (8) bolts to 65 ft. -lbs. (88 Nm) torque.
4 — 7.8 Removing the Drop Gear and Pinion Shaft The tools listed will be needed to do the following procedure: MEL-1151 — Pinion Cup Remover MEL-1 149 — Flange Holding Tool MEL-1145 — Bearing Remover MEL-1 152 — Handle MEL-1 1 50 — Flange Remover MEL-1 1 53 — Pinion Cup Remover NOTE:
Only the rear axle has a drop gear. Both the front and the rear axle have pinion shafts. The following procedure will identify which are for the rear axle only.
B-5046
Fig. 4-51
Removing Yoke from Pinion
To remove the drop gear and pinion shaft: (1) Use the flange holding tool to hold the yoke then remove the nut and washer from the end of the pinion shaft (Fig. 4 — 50).
(2) Use the flange remover to remove the yoke from the pinion shaft (Fig. 4-51).
(3)
If the yoke is worn at the seal surface, replace the yoke.
(4) Hold the pinion with your hand and use a soft hammer to hit the pinion shaft to remove it from the differential housing. Remove the outer bearing. (5)
Inspect the bearing and race. Replace them if necessary.
-4-11131 of 252
2000 RTF Service Manual
(6) Use the bearing remover to remove the bearing from the pinion shaft (Fig. 4 — 52).
NOTE:
See paragraph 4 — 7.4 step 2 for correct procedure for using the bearing remover.
(7) Rear Axle Only: Remove the drop gear and spacer from the differential housing (Fig. 4—53). (8) Use a slide hammer to remove the seal and back-up washer (Fig.
B-4783
Fig. 4-53
4-54).
Removing Drop Gear
Use the pinion remover and handle and a hammer to remove the outer pinion bearing race (Fig. (9)
4-55).
Fig. 4
Removing Bearing from Pinion
(10) Use tool #MEL-1153 and a hammer to remove the inner pinion bearing race (Fig. 4 — 56).
NOTE: Your axle may have an oil slinger installed with the shims under the inner bearing race. The oil slinger is not needed. Whe installing race, install additional shims the same thickness as the oil slinger.
—
B-4847
Fig. 4-54
A
Explanation of Assembly Procedure A simple explanation of the installation of the pinion, differential assembly and bearings is given below (Steps A thru D). See paragraphs 4 — 7.9 thru 4 — 7.1 5 for detailed installation procedures. A.
Removing Seal
Resle
(11) Measure the total thickness of all the shims (Fig. 4 57) and make a record of this thickness. You will use the same thickness of shims when installing an old bearing and race (Page 4—14, Step 1).
Find the total end play of the differential assembly without the pinion shaft installed. Install the pinion shaft correct position.
at
the B-5020
Fig. 4-55
Value on End of Pinion Shaft " + " Value
Removing Outer Pinion Race
Means •Mounting distance of pinion is increased. •Remove shims.
Value
•Mounting distance of pinion is decreased. •Add shims.
'0" Value
•Mounting distance is 3.500". •No shim change
needed.
132 of 252
B-501 2
B-5029
Fig. 4-56
Removing Inner Pinion Race
-4—12-
Fig. 4-57
Measuring Shim Thickness
2000 RTF Service Manual
.
C.
Find the total end-play of the differential assembly with the pinion shaft installed. This dimension will be the amount of shim thickness necessary for the ring gear side of the differential assembly.
D.
Subtract "C" from "A" above and then add 0.01 5" (preload) to the remainder and this dimension will be the amount of shim thickness necessary for the opposite side of the differential assembly.
EXAMPLE: "A" "C"
"D"
0.098" End-play without pinion installed -0.047" Shim thickness for ring gear side = 0.051" End-play for side opposite ring gear + 0.01 5" Add preload to opposite side = 0.066" Shim thickness for opposite
side NOTE:
Ring Gear Side
"A"
Pinion Side
__
"C"
Add Preload
1-501 1
Fig. 4-58
Installing End-play Tools
+ 0.01 5" + 0.01 5"
"D"
The chart to the right of the example above can be used to calculate shim thickness.
4 — 7.9 Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)
Check the differential assembly endplay as follows:
The tool listed will be needed to do the following procedure:
MEL-1 1 54 — Master Differential Bearing (Set of 2)
The illustrations for this procedure show the rear differential assembly (with limited slip differential). The procedure for checking the front is the same.
IMPORTANT
THIS PROCEDURE MUST BE COMPLETED WITHOUT THE PINION SHAFT AND GEAR INSTALLED.
Resle
NOTE:
( 1 ) Use tool #MEL-1 1 54 (set of two pieces) to install the master differential bearing on the hubs of the differential assembly (Fig. 4 — 58) where the bearings will normally be installed. Make sure the hubs of the differential assembly do not have any grooves or scratches and make sure that the tool will turn freely on the hubs. (2) Install the differential assembly (with tool installed) into the differential housing. (3) Install a dial indicator on the housing as shown in figure 4 — 59. (4) Put the tip of the dial against a flat surface of one of the ring gear bolts (Fig. 4 59). Mark this bolt with chalk.
—
NOTE:
Make sure that you mark this bolt. You will use this same bolt for measuring when installing the differential assembly.
(5) Push the differential assembly as far as possible toward the dial indicator hold the assembly in this position and set the dial to zero (0).
-5079
Fig. 4-59
Checking End Play
-4-13133 of 252
2000 RTF Service Manual
NOTE: (6)
The dial must have a minimum of 0.200" (5,08 mm) of movement.
"Push the differential
assembly as far as it will go away from the dial
indicator. (7) Record the reading which is on the dial. This is the total end play of the differential assembly. This is the total amount of shims required (less pre-load and will be used later during assembly (Page 4— 1 8, paragraph 4 — 7.14).
EXAMPLE: 0.098" Total end play of the differential assembly when the pinion shaft and gear is not installed.
4—7.10 Installing the Pinion Shaft Bearings
B-4843
Fig. 4 — 60
Install old race and bearings as follows:
Installing Inner Race
The tools listed will be needed to do the following procedure: MEL-1 1 58 — Pinion Cup Installer MEL-1 1 59 — Pinion Bearing Cone Replacer MEL-1 1 60 — Pinion Cup Installer
IMPORTANT
DO NOT USE OLD RACES AND BEARINGS IF YOU ARE INSTALLING NEW RING GEAR AND PINION.
Install the same thickness shims as was removed (See page 4—13, step 1 1 ) between the housing and the inner race.
B-4850
(1 )
(2)
Fig. 4-61
Installing Outer Race
Use tool #MEL-1 1 58 to install the inner pinion race (Fig. 4 — 60).
Install new race and bearings as follows: Use tool #MEL-1 1 58 to install the new inner race without shims. You will need to install the race without shims so that you can check the position of the pinion shaft (for backlash setting). (2)
Resle
(1 )
Use tool #MEL-1 1 60 to install the outer pinion race (Fig. 4 — 61).
IMPORTANT
IF YOU ARE REPLACING THE DIFFERENTIAL ASSEMBLY BEARINGS AND RACES OR THE RING GEAR, IT WILL BE NECESSARY FOR YOU TO CHECK THE END-PLAY OF THE DIFFERENTIAL ASSEMBLY. THE ENDPLAY OF THE DIFFERENTIAL ASSEMBLY MUST BE CHECKED WITHOUT THE PINION SHAFT AND GEAR IN PLACE, SO YOU MUST DO THAT PROCEDURE NOW BEFORE YOU CONTINUE WITH THE INSTALLATION OF THE PINION SHAFT (SEE PAGE 4-13, PARAGRAPH 4-7.9).
4—7.1 1 Installing the Pinion Shaft Install the pinion shaft as follows: NOTE:
The pinion gear and the ring gear are a set. If one is worn or damaged, both of the gears must be replaced.
134 of 252
-4-14-
2000 RTF Service Manual
(1 ) The ring gear and the pinion have numbers on them. Check the numbers. If the numbers are the same (Fig. 4 — 62), you know that the ring gear and pinion are a matched set. (2) You will also find a plus ( + ) number, or a minus ( — ) number, or a "O" on the flat surface of the pinion gear. This number indicates the best running position for this particular gear set and you will use this number to determine the correct shims to use when installing the pinion. (3) The standard dimension from the centerline of the ring gear to the flat surface on the end of the pinion gear is 3.500" (88,90 mm) (Fig. 4 — 63, Item 1). B-4856
Examples of how to read the numbers are as follows:
Fig. 4-62
Ring Gear & Pinion Numbers
" + 3" on the end of the pinion.
This means that by removing shims (Fig. 4- 63, Item 4), the mounting distance is increased to 3.503" ( 3,98 mm) (Item 2).
NOTE
When the number is a plus ( + ), you subtract the amount from the shim thickness which moves the pinion away from the centerline of the ring gear.
"-3" on the end of the pinion. This means that by adding shims (Fig. 4 — 63, Item 4), the mounting distance is decreased to 3.497"
1-
2. 3. 4.
Standard Dimension increased Mounting Distance Decreased Mounting Distance Shim
(88,82 mm) (item 3).
NOTE:
When the number is a minus (-), you add the amount to the
shim thickness which moves the pinion closer to the centerline of the ring gear.
3.500
"0" on the end of the pinion. This means that no additional shims are needed between the housing and the inner race and that the mounting distance will be 3.500" (88,90 mm) (Item 1).
4—7.12 Setting Pinion Shaft Position (Using Tool Pinion Shaft NOT Installed)
—
3.503
T_
TT
® Fig. 4-63
3.497' B-4808
Resle
Centerline of Ring Gear
Setting Position of Pinion Shaft
Set pinion shaft position as follows: The tools listed will be needed to do the following procedure:
MEL-1 1 53 MEL-1 1 55 MEL-1 1 58
Pinion Cup Remover Pinion Depth Gauge Pinion Cup Installer
(1) Install both new bearings into the races and install tool #MEl-1 1 55 through the bearings (Fig. 4-64).
(2) Tighten requires 50
the tool until it in.-lbs. (6,8 Nm) torque to turn the bearings in the races (Fig. 4 — 65). This amount of torque will equal the force as if the pinion itself were installed.
Fig. 4-64
Installing Pinion Depth Tool
-4-15135 of 252
5021
B-5032
Fig. 4
Checking Pinion Pre-ioad
2000 RTF Service Manual
(3) Install the 4-1/8" diameter tube (Tool #MEL-1155) into the differential housing. Install the bearing caps over the tube (Fig. 4 — 66). Make sure the letter on the caps match the letters on the housing (See Fig. 4 — 35). (4) Use a feeler gauge to check the dimensions between the bottom of the tube and the top of the other part of the tool (Fig.
4-66).
EXAMPLE:
0.065"
(5) Record this dimension and either add or subtract the values given on the flat surface of the
pinion gear.
1-5023
B-5014
Fig. 4 — 66
Checking Pinion Depth
Fig. 4-67
Installing Pinion Shaft
Fig. 4-68
Installing Inner Bearing
EXAMPLE: 0.065" Dimension between the tool parts (example only) (Fig. 4 — 66) (See Fig. 4 — 62). When the number is a minus (-), you add this amount to the shim thickness.
+ 0.003" If -3 is the number on the flat surface of the pinion
0.068"
The thickness of shims required between the housing and the inner pinion race (Fig. 4 — 63, Item 4).
Remove the pinion depth gauge (Tool #MEL-1 1 55) from the housing.
(7)
Your axle may have had an oil slinger installed with the shims under the inner bearing race. This oil slinger is not needed. Install only shims.
NOTE:
Resle
(8) Use the pinion cup remover (Tool #MEL-1 1 53) and a hammer to remove the inner pinion race. Install the shims into the housing (Fig. 4 — 63, Item 4), then install the race using the pinion cup installer (Tool #MEL-1 1 58).
(9) Rear Axle Only: Install the drop gear into the housing with the large hub of the gear toward the outside of the housing (Fig. 4 — 67, Item 1).
Use tool #MEL-1 1 59A to install the bearing on the pinion shaft of the front axle and tool #MEL-1 1 59B to install the bearing on the pinion shaft of the rear ( 1 0)
B-5031
axle (Fig. 4 — 68). (11) Rear Axle Only: Install the spacer (with counter bore) on the pinion shaft. The counter bore goes toward the bearing (Fig. 4 — 67, Item 2). Install the pinion shaft through the bearing races and through the drop gear. (1 2) Rear Axle Only: Install the spacer on the pinion shaft and slide it through the outside bearing race against the drop gear. The shoulder of the spacer goes toward the outside of the housing (Fig. 4 — 69, item 1 ).
4 — 7.13 Setting Pinion Bearing Pre-Load
Set pinion bearing pre-load as follows:
The tools listed will be needed to do the following procedure: MEL-1 149 — Flange Flolder MEL-1 1 55 — Pinion Depth Gauge MEL-1 161 — Pinion Seal Replacer MEL-1 1 62 — Yoke Installer MEL-1 1 64 — Second Check Block Install enough shims to equal 0.040" (1 ,02 mm) on the shaft (Fig. 4 — 69, Item 2) against the spacer (Item 1 ).
1.
Spacer
2,
Shims
3. 4.
Bearing Oil Slinger
B-5076
(1 )
136 of 252
-4-16-
Fig. 4-69
Installing Bearing
2000 RTF Service Manual
NOTE:
These shims are for bearing pre¬ load only (outer bearing) and will not affect the position ofthe pinionshaft(Fig.4 — 70, Item 1).
(2) Install the outside pinion bearing (Fig. 4 — 69, Item 3).
(3)
Install the oil slinger (Fig.
4 — 69, Item 4).
NOTE:
The oil seal must not be in¬ stalled until the pre-load is set.
(4) Install the yoke (Fig. 4 Item 1 ) on the pinion shaft.
— 71,
(5) Install the yoke installer (Tool #MEL-1 1 62) on the threads of the pinion shaft (Fig. 4 — 71, Item 2).
B-507 5
B-4808
Fig. 4-70 Tighten the tool (with your hand only) until the outside bearing is completely installed on the pinion shaft.
Fig. 4-71
Setting Pinion Pre-Load
Installing Yoke & Tool
(6)
(7)
Remove the tool from the
pinion shaft. (8) Install the old washer and nut on the pinion shaft to hold the yoke in position. (9) Put silicone sealant on the surface of the housing where the cover will be installed (Fig. 4 — 72).
Install the cover and bolts (Fig. 4 — 73). Tighten the bolts to 30 ft. -lbs. (41 Nm) torque. (11) Install tool #MEL- 1 1 49 on the yoke (Fig. 4 — 74, Item 1). (1 2) Tighten the nut to (346 Nm) torque.
B-4782
B-478 1
Fig. 4-72
Applying Sealant for Side Plate
pjg, 4
— 73
Installing Side Plate
255 ft. -lbs.
(13) Remove the tool from the yoke.
(1 4) Use a torque wrench to check the torque required to keep the pinion shaft turning (Fig. 4 — 75). The correct torque must be 20 - 30 in. -lbs. (2,26 - 3,39 Nm) torque.
(15) If the torque is not correct, remove the nut, washer, yoke, oil
slinger and bearing. (16) To increase the pre-load, re¬ move shims. To decrease the pre¬ load, add shims. For every 0.001 " (0,025 mm) of shim thickness the torque will change approximately 1 0 in. -lbs. (1,13 Nm). (17) To set the correct pre-load, increase and decrease the shim thickness as necessary and repeat steps 2 thru 1 2.
B-507 2
Fig. 4-74
Installing Yoke for Pre-Load
-4-17137 of 252
2000 RTF Service Manual
Resle
(10)
NOTE:
Recheck the pinion shaft posi¬ tion (Steps 18 thru 23) before continuing with pre-load set¬ ting (Steps 24 thru 28).
(18) Before you install the oil seal and back-up washer recheck the position of the pinion shaft (for backlash setting). (19) Install the 4-1/8" diameter tube (#MEL-1 155) into the differential housing (Fig. 4 — 76, Item 1 ) and install the bearing caps over the tube (Fig. 4—76). The letters on the caps must match the letters on the housing. (20) Put the second check block (Tool #MEL-1 1 64) on the flat
surface of the pinion gear (Fig. 4-76, Item 2).
B-507 7
8-507 3
Fig. 4-75
Checking Pinion Pre-load
(21) When using the second check block (Tool #MEL-1 1 64), you must use a 0.020" (0,51 mm) feeler gauge plus or minus a feeler gauge equal to the amount which is on the end of the pinion shaft.
Fig. 4-76
Rechecking Pinion Depth
Too! Parts
NOTE: The correct amount of measured clearance is 0.020", if the number etched on the end of the pinion shaft is "0". If the number etched is a plus ( + ), you must subtract the amount in shims. If the amount etched is a minus ( — ), you must add the amount in shims (in thousandths).
The number etched on the end of the pinion shaft is " + 3". Remove shims until the total measured clearance is 0.023", if the number etched is " — 2", add shims until the measured clearance is 0.018"
EXAMPLE:
(Fig. 4-77).
(23) If this thickness feeler gauge does not fit, you must add or remove shims (Fig. 4 77, Item 1) until you get this dimension (0.023" [per this example]).
—
Check With Feeler Gauge Here
Add or
Remove Shims Here For Pinion Depth
Setting
(24) When the pre-load is correct, remove the nut, washer and yoke. B-6235
(25) Put grease on the inside diameter of the new seal.
Fig. 4-77
Rechecking Pinion Shaft Position
(26) Install the new seal using the pinion seal replacer (Tool #MEL-1 161). The oil seal has a spring on the outside of rubber. The side with the spring goes into
the housing first. (27) Install the yoke, washer and new locknut. (28) Tighten the locknut to 260 ft. -lbs. (353 Nm) torque.
4
— 7.14 Installing Differential Assembly & Checking End Play (Pinion Shaft Installed)
Install the differential assembly as follows: MEL-1 144 — Differential Housing Spreader MEL-1 1 54 — Master Differential Bearing MEL-1 1 63 — Carrier Bearing Cone Replacer
IMPORTANT
THIS PROCEDURE MUST BE COMPLETED WITH THE PINION SHAFT AND GEAR INSTALLED.
Install the master differential bearing (Tool #MEL-1 1 54) on the hubs of the differential assembly (Fig. 4 — 78).
B-501 1
(1 )
-4-18138 of 252
Fig. 4-78
Installing Tool
2000 RTF Service Manual
Resle
(22) There is a tolerance of ±0.002" (0,051 mm), so if a feeler gauge of 0.021 - 0.025" (0, 533-0,635 mm) (Per this example) will fit between the tool parts, the position of the pinion shaft is correct.
(2)
Install the differential assembly (with tool installed) into the housing.
(3) Install a dial indicator on the housing with the tip of the dial on the flat surface of the same bolt which you marked with chalk in Paragraph 4 — 7.9, Step 4 (Fig. 4—59). (4) Push the differential assembly away from the dial indicator as far as possible so that the teeth of the ring and pinion are tight against each other. (5) Hold the differential assembly in this position and set the dial indicator to zero (0).
(6) Move the differential assembly toward the dial as far as possible to get a reading on the dial. Move the differential assembly several times until you get the same reading each time. (7) This reading is the dimension of the shims needed between the differential assembly bearing and the differential assembly on the ring gear side. Make a record of this reading.
B-507
Fig. 4-79
Installing Shims
EXAMPLE: 0.047" (8)
Remove the differential assembly from the housing and remove the tool.
(9) To get the correct thickness of shims on each side of the differential assembly, use the example below.
EXAMPLE: 0.098"
From page 4—14, paragraph 4 — 7.9, step 7. This is the total end-play of the differential assembly without the pinion shaft and gear installed.
— 0.047" From page 4—19, paragraph 4 — 7.1 1 , step 7. This is the total end-play
= 0.05 1 "
Total end play on the side opposite the ring gear.
+ 0.01 5" Add this
1-5074
amount for pre-load.
Fig. 4
= 0.066"
This is the correct thickness of shims for the opposite side of the differential assembly.
— 80
Resle
(ring gear side) of the differential assembly with the pinion shaft and gear installed. This is the correct thickness of the shims for the ring gear side of the differential assembly.
Installing Bearing
(1 0) Put the correct thickness of shims (0.047" [per this example)) on the hub of the differential assembly (ring gear side) and install the bearing using tool #MEL-1 163 (Fig. 4-79 and Fig. 4-80).
NOTE:
If you are using the old bear¬ ings, install them on the same side from which you removed them.
(11) Put the correct thickness of shims (0.066" [per this example]) on the hub of the differential assembly (opposite side) (Fig.
4-81).
(12) Use the carrier bearing cone replacer (Tool #MEL-1163) to
install the bearing on the opposite side of the differential assembly (Fig. 4-82).
I-5082
Fig. 4
Installing Bearing
-4-19139 of 252
Fig. 4-82
Installing Bearing
2000 RTF Service Manual
(13) Install spreader tool (Fig. 4-83, Item 1) (Tool #MEL-1 144) on the housing. Install two bolts and tabs as shown (Fig. 4 — 83, Item 2).
the 83, the the opening in the housing and the tip of the dial is on the other side of the opening. (14) Install a dial indicator on housing as shown (Fig. 4 — Item 3) so that the base of indicator is on one side of
(1 5) Set the dial indicator to zero ("0").
B-5070
Fig. 4-83
Installing Spreader Tool
Fig. 4-84
Installing Differential Assembly
IMPORTANT Do not bend the differential housing more than 0.015" (0,38 mm).
(1 7) Install the bearing race on the bearings and install the differential assembly into the housing. You may need to hit the assembly with a soft hammer to install it into the housing (Fig. 4 — 84).
Resle
(16) Turn the spreader bolt until the dial indicator shows 0.015" (0,38 mm).
(18) Install the bearing caps over the races and tighten the bolts a small amount (Fig. 4-85).
NOTE:
Be sure to install the caps on the correct side (Fig. 4 — 85).
(19) Remove the spreader tool (Tool #MEL-1144) and the dial
NO
indicator.
(20) Tighten the bolts in the bearing caps to 80 ft. -lbs. (108 Nm) torque.
B-4814
Fig. 4-85
Installing Bearing Caps
-4 — 20140 of 252
2000 RTF Service Manual
4 — 7.15 Checking Gear Backlash
Check gear backlash as follows: (1) Install the dial indicator on the housing and put the tip of the dial indicator against one tooth of the ring gear (Fig. 4 — 86). OF
(2) Turn the ring gear towards the dial indicator until the teeth of the pinion and ring gear are tight against each other.
Hold the ring gear in this position and set the dial to zero
(3)
("0"). (4) Turn the ring gear away from the dial and check the reading on the dial. (5) Repeat steps 2, 3 and 4 at three equally spaced locations on the ring gear.
The correct backlash must be 0.005 - 0.009" (0,127 - 0,228 mm) and the difference between the maximum and the minimum readings must not be more than 0.003" (0,076 mm). (6)
(7)
Fig. 4
— 86
Checking Tooth Engagement (Backlash)
if the difference is more than 0.003" (0,076 mm), you must replace the ring gear and the pinion gear. If the backlash is not correct (0.005 - 0.009") change it as follows:
Resle
NOTE:
1-4837
High backlash is corrected by moving the ring gear closer to the pinion.
EXAMPLE:
0.020" 2 0.010"
Too high backlash (correct backlash is 0.005 - 0.009"). Divide backlash by 2 Remove this thickness of shim(s) from the opposite side and put this amount of shims on the ring gear side.
rr B-4785
Fig. 4-87
Applying Sealant for Cover Plate
Low backlash is corrected by moving the ring gear away from the pinion.
EXAMPLE:
0.003" x 1
0.003"
Too low backlash Multiple times one (1 ) Remove this thickness shim from the ring gear side and put this amount of shims on the opposite side.
(
//, flu
Push the axles into the differential assembly so that the splines are engaged. (8)
(9) Install 12 cone washers and 1 2 locknuts on the studs and tighten the nuts to 100 ft. -lbs. (1 36 Nm) torque. (1 0) Put silicone sealant on the surface of the housing where the covers installed (Fig. 4 — 87 and 4 — 88).
141 of 252
-4 — 21-
will be
\
w W \
Fig. 4-88
V
;
xTx! B-4781
Applying Sealant for Side Plate
2000 RTF Service Manual
(11) Install both cover and the bolts (Fig, 4 — 89 and 4 — 90). Tighten the bolts to 30 ft. -lbs. (41
(TVZjrv
Nm) torque.
'
fl~ (12) Add lubricant to the differential housing after installing on the machine.
NOTE:
,)
On the rear axle also add 402 limited slip additive.
ÿ B-4782
B-4788
Fig. 4-89
Fig. 4-90
Installing Cover Plate
Installing Side Plate
4-8 PARKING BRAKE
4 — 8.1 Description
Disc Brake 8. Nut Cable 9. Nut 3. Control Lever 10. Mount 4. Clevis 11. Bolt 5. Caliper 12. Nut 6. Cotter Pin 13. Hydraulic Motor Shaft 7. Pin 1.
2.
The parking brake consists of a disc brake assembly (Fig. 4 — 91, Item 1) mounted on the hydrostatic motor, a cable (Item 2) with attaching parts and a control lever (Item 3) that operates the brake.
The parking brake is engaged by pulling the lever up into the locked position.
IMPORTANT
d>ÿ Resle
The parking brake lever must be in the locked position when the Bobcat Forklift is stopped and before the operator gets off the Bobcat Forklift.
4 — 8.2 Adjusting the Parking Brake Adjust the parking brake as follows:
Remove the set screw from the lever of the parking brake (Fig. (1)
B-5673
Fig. 4
— 91
Disc Brake Assembly
4-92).
(2) Turn the lever to adjust brake for correct "over center" action. Turning the lever clockwise will tighten the brake (Fig. 4 — 93).
NOTE: When you cannot adjust the brake any more, the brake pads are worn. Replace worn brake pads. Install the set screw in the lever of the parking brake.
Fig. 4-92
Parking Lever Set Screw
-4-22142 of 252
B-567 5
B-5674
(3)
Fig. 4-93
Adjusting the Parking Brake
2000 RTF Service Manual
4 — 8.3 Removing the Parking Brake Cable Remove the brake cable as follows: ( 1 ) Disconnect clevis (Fig. 4 — 9 1 , Item 4, Fig. 4 — 94, Item 1 ) from caliper (Fig. 4—91 , Item 5 and Fig. 4 — 94, Item 2) by removing cotter pin (Fig, 4—91 , Item 6 and Fig. 4 — 94, Item 3) and pin (Fig. 4 — 91 , Item 7 and Fig. 4 94, Item 4).
—
(2) Remove clevis (Fig. 4 — 91, Item 4) from end of brake cable (Fig. 4 — 91, Item 2) by removing lower nut (Fig. 4 — 91 , Item 8).
Remove bottom nut (Fig. 4 — 91 , Item 9) from mount (Fig. 4 — 91, Item 10) (Fig. 4 — 95). Pull cable (Fig. 4 — 91 , Item 2) through the hole in the mount (Fig. 4 — 91, Item 1 0). (3)
1. 2. 3. 4,
4
5. 6.
— 8.4 Installing the Parking Brake Cable
Clevis Caliper
Cotter Pin Pin Brake Caliper Celvis Bolt
Fig. 4-94
8-5676
Parking Brake Cable
Install the brake cable as follows:
Put the end of the cable (Fig. 4 — 91 , Item 2) through the hole in mount (Fig. 4 — 91, Item 1 0). Install nut (Fig. 4 91, Item 9) and tighten (Fig. 4 — 95).
(1 )
—
(2) Install clevis (Fig. 4 — 91 , Item 4) on end of brake cable (Fig. 4 — 91 , Item 2) by installing lower nut. (3) Connect clevis (Fig. 4 — 91, Item 4) to caliper (Fig. 4 — 91, Item 5) by installing pin (Fig. 4 — 91, Item 7) and cotter pin (Fig. 4 — 91, Item 6).
4
— 8.5 Removing the Parking Brake Assembly from the Hydrostatic Motor Resle
NOTE: The parking brake assembly cannot be removed from the hydrostatic motor unless the hydrostatic motor is removed from the machine. To remove the parking brake assembly from the hydrostatic motor (Fig. 4 — 91): (1 ) Remove the hydrostatic motor from the machine (See Paragraph 3 — 7.1 , Page 3 — 27). Put the hydrostatic motor in a vise.
Remove four (4) bolts (Fig. 4 — 9 1, Item 1 1) that fasten caliper (Fig. 4 — 91 , Item 5) to mount (Fig. 4—91, Item 10). Remove caliper from mount (Fig.
(2)
4-96).
NOTE:
8- 5677
Fig. 4-95
Removing the Lower Nut
There is a spring that holds the brake pads away from the disc brake. The spring has tension so remove the brake pads from the caliper carefully.
/a
\ a
(3)
Check the brake pads for wear or damage. Replace as necessary.
,
/0
/ 0/
—
(4) Remove nut (Fig. 4 91 , Item 12) that fastens disc brake (Fig. 4 91, Item 1) to the hydrostatic motor shaft (Fig. 4 97).
—
—
B-5679
Fig. 4
Removing the Caliper
-4-23143 of 252
Fig. 4-97
Removing the Disc Nuts
2000 RTF Service Manual
(5) Use a gear puller to loosen disc brake (Fig. 4 — 98). Remove disc brake from hydrostatic motor shaft (Fig. 4 — 99).
(6) Remove the mount (Fig. 4 — 91, Item 10) from the hydrostatic motor housing (Fig. 4-100).
B-5680
Fig. 4 — 99
Removing Disc Brake
—
4 8.6 Installing the Parking Brake Assembly on the Hydrostatic Motor Housing
B-57 37
Fig. 4-98
NOTE:
Removing Disc Brake
'mk
You can install the brake assembly on the hydrostatic motor before or after you install the hydrostatic motor in the machine.
Install the parking brake assembly on the hydrostatic motor as follows (Fig. 4 — 91 ): B-5681
Fig. 4-100
Removing Brake Mount
(1) Install the mount (Fig. 4 — 91, Item 10) on the hydrostatic motor (Fig. 4-100).
(3)
4 — 91 , Item 1 ) on the hydrostatic motor shaft (Fig.
Resle
(2) Install disc brake (Fig. 4-99).
Install nut (Fig. 4 — 91 , Item 1 2) and tighten (Fig. 4 — 97).
(4) Be sure the spring is put in the correct position between the brake pads and install caliper (Fig. 4 — 91, item 5) and install four (4) bolts (Fig. 4 — 96).
144 of 252
-4-24-
2000 RTF Service Manual
..
MAIN FRAME
ASSEMBLING THE BOBCAT FORKLIFT DISASSEMBLING THE BOBCAT FORKLIFT DOORS FLOORPANELS FUEL TANK OPERATOR GUARD REAR GRILL SEAT AND SEAT PLATE VERTICAL MAST
Paragraph Number
Page Number
5-8
5-6
5-7 5-6 5-3 5-5 5-1 5-2 5-4 5A
5-4 5-3 5-1 5-3 5-1 5-1 5-2 5A-1
..
MAIN FRAME
A WARNING
Resle
VERTICAL MAST
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
2000 RTF Service Manual 145 of 252
Resle 146 of 252
5 MAIN FRAME 5-1 OPERATOR CAB The Bobcat forklift has a rollover protective structure (ROPS) as standard equipment. It also protects the operator from falling objects (FOPS).
A WARNING Never change the operator cab by welding, grinding, drilling holes or adding attachments that are not approved. This can weaken the operator cab and cause personal injury or death.
Fig. 5-1
Rear Grill Nuts
5-2 REAR GRILL 5 — 2.1 Removing the Rear Grill (1) Remove the nuts at the rear grill (Fig. 5-1 ). (2)
Remove the rear grill from the machine (Fig. 5 — 2).
5 — 2.2 Installing the Rear Grill
(2)
25
-
Install the nuts and tighten to 28 ft. -lbs. (34 - 38 Nm)
torque. 8-46 1 2
5-3 FLOORPANELS
pig 5 — 2
Resle
(1) Install the rear grill on the machine (Fig. 5 — 2).
Rear Grill
5 — 3.1 Removing the Floorpanels
Remove the two floorpanels as follows: (1)
Remove floormat.
(2) Remove four bolts and remove the front floorpanel (Fig. 5-3).
(3) Remove two bolts and remove the rear floorpanel (Fig. 5-4).
5 — 3.2 Installing the Floorpanels
Install the floorpanels as follows: (1 ) Install the rear floorpanel and install two bolts. (2) Install the front floorpanel and install four bolts. (3)
Install the floormat.
Fig. 5-3
Removing Front Floorpanel
-5-1147 of 252
-5685
.-5685
Fig. 5-4
Removing Rear Floorpanel
2000 RTF Service Manual
5-4 SEAT AND SEAT PLATE 5 — 4.1 Removing the Seat and Seat Plate (1) Remove the floormat and remove both floorpanels (See Paragraph 5 — 3.1 ).
(2) Loosen bolt (Fig. 5 — 5, Item 6) that fastens bell crank (Item 5). -568
Fig. 5-6
(3) Remove L-shaped end of the throttle linkage (Fig. 5 — 5, Item 7) from bell crank (Item 5).
Removing Lower Bolts
B-5687
Remove the two bolts that fasten the seat plate to the floor (Fig. 5-6), (4)
Fig. 5-5
Throttle Linkage
(5) Remove the 2 bottom bolts that fasten the door to the rear of the ROPS to the frame. This will give clearance to move the seat and seat plate forward (Fig. 5-7).
(6) Remove the two upper bolts that fasten the seat plate to the frame (Fig. 5-8).
(7) Remove the seat and seat plate (Fig. 5 needed.
i-5689
Fig. 5-7
Removing the Lower ROPS Bolt
Fig. 5-9
Removing Seat and Seat Plate
— 9) as an assembly. Two people are Resle
5 — 4.2 Installing the Seat and Seat Plate (1 )
Put the seat and seat plate in place.
(2)
Install 2 bolts that fasten the seat plate to the floor (Fig. 5 — 6).
(3) Install 2 bolts that fasten the seat plate to the frame (Fig. -5 8).
—
~T/
Seat Beits
(4) Install 2 bolts that fasten the door to the rear of the ROPS to the frame (Fig. 5 — 6).
(5) Install L-shaped end of linkage (Fig. 5 — 5, Item 7) into bell crank (Item 5).
Tighten bolt that fastens the bell crank (Fig. 5 — 5, Item 6).
(6)
Install the floorpanels and floormat.
B-5690
(7)
Fig. 5-8
Removing Upper Bolts
-5-2148 of 252
2000 RTF Service Manual
5-5 FUEL TANK 5 — 5.1 Removing the Fuel Tank (1 )
Use a syphon to remove the fuel from the tank.
(2)
Remove the seat and seat plate (See Paragraph 5 — 4.1).
(3)
Disconnect the hoses from the fuel tank. Plug the hoses.
(4)
Disconnect the wires connected
to
the fuel tank at the wire harness
connector.
(5)
Remove the fuel tank (Fig. 5—10).
5 — 5.2 Installing the Fuel Tank (1 )
NOTE:
Put the fuel tank in place. Make Sure the rubber around the filler neck is in the correct position.
(2)
Connect wires to the fuel tank.
(3)
Connect hoses.
(4)
Install the seat and seat plate (See Paragraph 5 — 4.2).
5-6 DOORS 5 — 6.1 Removing the Rear Door Remove the rear door as follows (Fig. 5—11):
Lift and block the machine (See Paragraph 1 —2, Page 1 — 1 ).
(2)
Disengage the door latch.
Resle
(1 )
(3) Put a chain hoist on the door and the hooks in the elliptical shaped holes.
Fig. 5-10
Removing the Fuel Tank
(4) Remove the two hinge pins. Drive out the pins with a hammer and brass punch. (5) Remove the rear door with the chain hoist.
B-4568
5 — 6.2 Installing the Rear Door ;
B-4131
Install the rear door as follows (Fig. 5-11):
(1) Put the door in place and align the hinge pin holes.
(2) (3)
Install 2 hinge pins. Remove the chain hoist.
-5748
Fig. 5-11
Removing the Rear Door
-5-3149 of 252
2000 RTF Service Manual
5 — 6.3 Removing the Side Doors
nnn
Remove the seven (7) bolts (Fig. 5—12, Item 1 ) that fasten the mounting plates for the side doors (Item 2). (1 )
(2)
ÿffl
Remove the two (2) side doors.
5 — 6.4 Installing the Side Doors (1 )
Put the doors in place, lining up the bolt holes.
Install the seven (7) bolts (Fig. 5—12, Item 1 ). Adjust the door in position before tightening bolts.
(2)
C-2737
Fig. 5-12
Removing Side Doors
5-7 DISASSEMBLING THE BOBCAT FORKLIFT
5 — 7.1 Separating the Sections Separate the front section from the rear section of the Bobcat Forklift by using the following procedure: (1 )
Remove the vertical mast (See Paragraph 5A — 2, Page 5A— 1 ).
(2) Replace the front wheels and lower and remove the front jacks so the wheels are on the ground.
DO NOT remove the jacks under the rear of the machine after removing the vertical mast.
Resle
NOTE:
C-2738
Fig. 5-13
A WARNING
When disconnected, both the front and rear sections of the forklift must be blocked to prevent tipping. The rear section must be supported by jack stands under the two rear corners. The front section with vertical mast removed must have front wheels on and be supported by a jack stand under the front main frame at the oscillating link. Never operate the Forklift with the vertical mast removed. Failure to obey warning may cause injury or death.
(3)
Remove the drive shaft (See Paragraph 4 — 4.1, Page 4 — 2).
(4)
Put a floor jack under the front section of the machine (Fig. 5—13).
(5)
Disconnect the lift and tilt cylinder hoses from the control valve.
150 of 252
Lifting the Front Section
-5 — 4-
2000 RTF Service Manual
(6) Disconnect the pivots that fasten the two (2) sections together using the following procedure (Fig. 5-14): (a) Disconnect the pivot at the rod end of the steering cylinder (Fig. 5—15).
(b) Remove the top pivot bolt which is connected to the oscillating link (Fig. 5—16).
c
-5694
Remove the four (4) bolts from the retainer plate for the bottom pivot and remove the retainer plate (Fig. 5—17). (c)
Fig. 5-15
(d) Remove the nut which fastens the ball stud at the lower pivot point (Fig. 5—18).
(7)
Steering Cylinder Pivot
C-2739
ig. 5-14 Loader Pivots
Remove the steering frame lock.
5 — 7.2 Ball Stud & Race Assembly (Fig. 5—19)
The ball stud and race should be ordered pre-assembled (See Parts Fiche). If the ball stud and race are being assembled by the Bobcat technician, use the following procedure. The ball stud race has a crack so that it can be installed on the ball stud.
A WARNING (1)
Use a protective shield around the parts when using a hydraulic press to install or remove the race on the ball stud. By¬ standers need the shield for protection from possible flying parts during the press operation. The travel speed of the hydraulic press must be 2 inches (51 mm) per 5 seconds or slower. Failure to obey warnings can cause injury or death.
C-2740
Fig. 5-16
Upper Pivot
Use a press to remove the ball stud from the old race.
(2) Lubricate the new race and use the'hydraulic press to install the race on the ball stud.
NOTE:
(3)
When pressing the race onto the ball stud, do not stop the hydraulic press until the race is fully on the ball. Any hesitation in the pressing operation can result in the race fracturing forcefully.
Install a seal on the top of the race only.
5 — 7.3 Remove the Oscillating Link (1)
5695
Disassemble the Bobcat Forklift (See Paragraph 5 — 7.1)
Revised Oct. 83 151 of 252
-5-5
Fig. 5-17
Retainer Plate
2000 RTF Service Manual
Resle
NOTE:
(2) Remove the bolt from the rear of the oscillating link (Fig. 5 — 20).
(3)
Remove the oscillating link.
5-8 ASSEMBLING THE BOBCAT FORKLIFT B-5696
The tools listed will be needed to do the following procedure:
MEL-10043 MEL-10390
Wrench Torque Multiplier
Fig. 5 — 19 Ball
C-2741
— Torque —
Stud & Race Assembly
Fig. 5-18
Lower Pivot Nut
Use the following procedure to assemble the machine:
(1)
Install the oscillating link.
(2) Put the front section of the machine in place and make alignment of the pivot holes (Fig. 5—14).
Install the steering frame lock.
Resle
(3)
(4) Install the ball stud and race assembly into the lower pivot point. Install the nut (Fig.. 5— 18). Tighten the nut to 600 ft. -lbs. (813 Nm) torque.
B-5697
Fig. 5-20
NOTE:
(5)
Oscillating Link Rear Bolt
Use silicone sealant as sealer between the retainer plate and frame.
Install the retainer plate and the four (4) bolts (Fig. 5—17).
(6) Install the top pivot bolt (Fig. 5—16). Tighten the bolt to 950 ft. -lbs. ( 1 288 Nm) torque.
(7) install the rod end pivot of the steering cylinder (Fig. 5—15). Tighten the bolt to 950 ft. -lbs. (1288 Nm) torque.
(8)
Connect the lift and tilt cylinder hydraulic hoses to the control valve.
(9)
Install the drive shaft (See Paragraph 4 — 4.2, Page 4 — 2).
Revised Oct. 83
152 of 252
-5-6-
2000 RTF Service Manual
VERTICAL MAST
ADJUSTING CARRIAGE ROLLERS . . . ADJUSTING THE LIFT CARRIAGE . . . INSPECTING THE VERTICAL MAST.. INSTALLING THE CARRIAGE CHAINS INSTALLING THE LIFT CARRIAGE . . . INSTALLING THE MOUNTING FRAME INSTALLING THE VERTICAL MAST . . PALLET FORKS REMOVING THE CARRIAGE CHAINS . REMOVING THE LIFT CHARRIAGE . . REMOVING THE MOUNTING FRAME . REMOVING THE VERTICAL MAST . . REPLACING THE BRONZE BUSHING .
TROUBLESHOOTING
Paragraph
Page
Number
Number
5A-13 5A-10 5A — 4 5A-9 5A-12 5A-7 5A-3 5A-14 5A-8 5A-1 1 5A — 6 5 A— 2 5A-5 5A-1
5A — 7 5A — 6 5A-3 5A-5 5A-7 5A-5 5A — 2 5A-10 5A-5 5A-6 5A-4 5A-1 5A — 4 5A-1
Resle
VERTICAL MAST
AWARNING
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
2000 RTF Service Manual 153 of 252
Resle 154 of 252
5A- VERTICAL MAST The Bobcat Forklift has a double-stage vertical mast (upright). The lift cylinder for the vertical mast is offset to the right of the upright. Two (2) tilt cylinders are connected between the vertical mast and the front main frame of the machine. Two (2) carriage chains and a roller system control raising and lowering the vertical mast.
5A-1 TROUBLESHOOTING THE VERTICAL MAST
PROBLEM
KEY TO CORRECT THE CAUSE
CAUSE 1, 2
1.
Pivot Pins and bushings on the rod ends of the tilt cylinders are worn.
Mast is loose where mounting frame connects to the axle.
3
2.
Air in hydraulic cylinders.
Mast will tilt when the engine is not running.
4
3.
Bronze bushing is worn.
Mast will tilt forward too fast with heavy load.
4
4.
Counterbalance valve is not working correctly.
Mast will drop too fast with heavy load.
5
5.
Lift cylinder flow correctly,
Mast rocks forward.
backward and
restrictor is not working
AWARNING
Resle
5A — 2 REMOVING THE VERTICAL MAST
Never try to operate the Forklift with the vertical mast removed. The machine will tip. Failure to obey warnings will cause injury or death.
( 1)
Lift and block the Bobcat Forklift (See Paragraph 1—2, Page 1 — 1 ).
(2)
Install the frame lock.
(3)
Remove the front tires.
(4) Loosen the bolts on the split collars that connect the upright mounting frame of the vertical mast to the axles of the Bobcat Forklift (Fig. 5A-1).
(5) Attach the vertical mast to an overhead chain hoist (Fig. 5A — 2).
Remove the bolts from the split collar.
Fig. 5A— 1
Split Collar
-5A-1155 of 252
B-5874
8-5863
(6)
Fig. 5A-2
Attaching Mast to Chain Hoist
2000 RTF Service Manual
\>)
IMPORTANT
When making repairs on hydraulic system, keep all parts clean and remove all dirt from the area before you begin disassembly. Use caps and plugs to keep dirt out of tubelines and openings.
Disconnect the hose coming from the top (rod end) of the lift cylinder at the control valve (Fig. 5A — 3). (7)
(8) Disconnect the hose coming from the bottom (base end) of at the connection near the mounting frame (Fig. 5A — 4).
A WARNING
! \ // I
C/\ y-L-LMlILr/ÿ4 ~ W \ 1 ''
the lift cylinder
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or damage eyes. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use bare hand. Wear safety goggles. If fluid enters skin or eyes get immediate medical attention.
—_
|
8-5864
Fig. 5A — 3
Disconnecting Rod End Hose
Fig. 5A-5
Bolts and Pin Lock
(9) Remove the bolts and pivot pin locks from the rod ends of the tilt cylinders (Fig. 5A-5). (10) Use a punch and hammer to remove the pivot pin from the rod ends of the tilt cylinders (Fig. 5A — 6). (11) Use a pry bar between the mounting frame on the vertical mast and the front main frame of the machine to move the vertical mast away from the axles (Fig. 5A — 7).
(12)
Move the
vertical
mast
away from the machine with the
Resle
chain hoist.
5A-3 INSTALLING THE VERTICAL MAST (1) Move the vertical mast into position on the Forklift. (2) Connect the mounting frame to the axle of the machine by
installing the bolts through the split collar and the mounting frame (Fig. 5A— 1 ). Hand tighten the bolts.
B-5878
Fig. 5A-4
Disconnecting Base End Hose
(3) Connect the rod ends of the tilt cylinders to the vertical mast by installing the pivot pins, pin locks and bolts (Fig. 5A — 5). (4) Tighten the bolts on the split collar to 65 - 70 ft. -lbs. (88 - 95 Nm) torque. (5) Connect the hose coming from the rod end of the lift cylinder to the control valve (Fig. 5A — 3).
(6) Connect the hose coming from the base end of the lift cylinder to the connection near the mounting frame (Fig. 5A — 4).
156 of 252
-5873
B-5869
Fig. 5A-6
Removing Pin
-5A-2-
Fig. 5A-7
Separating Vertical Mast
2000 RTF Service Manual
(7)
Disconnect the vertical mast from the chain hoist.
(8) Start the engine and operate the control lever to check the operation of the vertical mast.
5A-4 INSPECTING THE VERTICAL MAST (1 ) Inspect the sheave carrier guide. Check for signs of hydraulic fluid leakage around the sheave carrier lock nut. Check for scratches on the guide rod. (2) Check that the sheaves turn easily with vertical mast operation. Check that they are free of signs of metal particles around the pivot shaft.
(3)
Check the vertical mast roll patterns. (a)
Put a thin layer of grease or a light coat of spray paint on the sheave
contact area. (b)
Operate the vertical mast with a load.
(c) Check for scratches. If roll patterns show that sheaves are damaged or out of adjustment, replace or adjust sheaves (See Paragraph 5A— 13).
(4)
Do a load test. (a) Put a capacity load on the forks and secure it load back a small amount.
to
the carriage. Tilt the
Raise the load to maximum height several times. Check for smooth operation, carriage play and play between rails.
(b)
(c) If operation is correct, put the load 4 inches off center and secure it to the carriage. Tilt the load back a small amount. (d) Raise the load to maximum height several times. Check for smooth operation, carriage play and play between rails.
(e) If operation is correct, put the load 4 inches off center in opposite direction and secure it to the carriage. Tilt the load back a small amount. (f)
Raise the load to maximum height several times. Check for smooth
(5)
Do a lift cylinder drift test. (a) Put a capacity load on the forks and secure it to the carriage. Tilt the load back a small amount.
Resle
operation, carriage play and play between rails.
(b) Raise the vertical mast half-way up or more. Turn the key-switch to the "off" position.
AWARNING (c)
Do not stand or pass under the load. The load can fall and cause injury or death to anyone standing under the vertical mast in a raised position.
Mark across the rails on one side of the upright with tape or a marking
pen.
NOTE:
Be sure the marks are in line from rail to rail. (d) Down drift will allow the inner rail to drop and the mark will not line up from rail to rail. (e) Maximum allowable down drift is one (1) inch per minute.
(6)
Replace or repair any parts that show signs of wear or damage.
-5A — 3157 of 252
2000 RTF Service Manual
5A-5 REPLACING THE BRONZE BUSHING There is a bronze bushing on the Bobcat Forklift where the vertical mast mounting frame connects to the axle of the machine. If the mounting frame is loose during operation of the vertical mast the bronze bushing must be replaced.
To replace the bronze bushing:
(1)
Remove the vertical mast (See Paragraph 5A — 2). Fig. 5A-8
Split Collar
(2) Loosen the bolts and remove the split collar that holds the bronze bushing in place on the axle (Fig. 5A — 8).
(3)
Remove the axle hub (See Paragraph 4 — 7.1 , Page 4 — 4).
(4) Use a screwdriver to separate the bronze bushing at the gap and remove it from the axle (Fig. 5A — 9).
(5) Install the new bushing on the axle up against the flange. Install it with the gap toward the ground. B-5870
Install the split collar (Fig. 5A — 8). Leave the bolts loose.
(7)
Replace the hub (See Paragraph 4 — 7.2, Page 4 — 5).
Fig. 5A-9
Bronze Bushing
Resle
(6)
(8) Put the split collar a maximum of .10" (2,54 mm) from the axle hub and tighten the bolts to 1 1 0 to 1 20 in.-lbs. (1 2,5 to 1 3,5 mm) torque.
(9)
Replace the vertical mast (See Paragraph 5A— 3).
B-5872
Fig. 5A-10
Mounting Frame
5A-6 REMOVING THE MOUNTING FRAME
( 1)
Remove the vertical mast (See Paragraph 5 A — 2).
(2) Put support blocks under the vertical mast and lower the vertical mast on the chain hoist (Fig. 5A— 10).
(3) Loosen and remove the eight (8) bolts on the ends of the mounting frame (Fig. 5A— 1 0, Item 1 ).
(4)
B-5867
Lift the mounting frame away from the vertical mast (Fig. 5A— 1 1).
Fig. 5A— 11 Mounting Frame
158 of 252
-5A — 4-
2000 RTF Service Manual
5A-7 INSTALLING THE MOUNTING FRAME (1)
Lift the mounting frame and put it in position of the vertical mast.
(2)
Install the bolts and tighten to 300 to 330 ft. -lbs. (407 to 447
NOTE:
Nm) torque.
After the first 25 hours of operation the bolts must be tightened again to 300 to 330 ft. -lbs. (407 to 447 Nm) torque. B-5865
Fig. 5A-12
Cotter Pin
5A-8 REMOVING THE CARRIAGE CHAINS ( 1)
Install the frame lock and engage the park brake.
(2)
Lower the vertical mast fully down.
(3) Remove the cotter pins and bolts that connect the carriage chains to the bottom left of the inner rail of the vertical mast and to the bottom right of the inner rail (Fig. 5A— 1 2).
Remove the cotter pins from the bolts holding the carriage chain anchor bolts.
5866
(4)
Fig. 5A-13
Carriage Chain Anchor Bolts
(5) Remove the jam nuts from the anchor bolts and pull them up throught the holes (Fig. 5A-13).
Resle
(6) Pull the chains up and over the rollers and away from the vertical mast (Fig. 5A-14).
5A — 9 INSTALLING THE CARRIAGE CHAINS Put one carriage chain over the front roller on the right side of the vertical mast and the left roller. Put the other chain over the back right roller (Fig.
B-5862
( 1)
Fig. 5A-14
Pulling Chains Out
5A-14).
(2)
Insert the anchor bolts into the holes on the outer rail of the vertical mast.
(3)
Install the jam nuts on the bolts (Fig. 5A— 1 3).
(4)
Install the cotter pins on the anchor bolts (Fig. 5A— 1 3).
(5) Install the bolts and cotter pins to connect the chains to the right and left bottom of the inner rail of the vertical mast (Fig. 5—1 2).
(6)
Adjust the lift carriage (See Paragraph 5A— 10).
-5A-5159 of 252
2000 RTF Service Manual
5A-10 ADJUSTING THE LIFT CARRIAGE (1 )
Move the machine to level ground.
(2)
Install the frame lock and engage the park brake.
(3)
Lower the vertical mast fully down,
(4)
Loosen the bottom jam nuts on the carriage chain anchor bolts. ÿ5860
(5)
Put a square on the top of the lift carriage (Fig. 5A— 1 5).
Fig. 5A-1 5
Adjusting Lift Carnage
(6) Loosen or tighten one of the top jam nuts on the anchor bolts until the square is aligned with the inside edge of the inner rail. Be sure both chains have equal tension.
Loosen or tighten one of the top jam nuts on the anchor bolts until one pallet fork is 1/2" (127 mm) from the ground (Fig. 5A — 16). Remember the number of turns on the nut. (7)
(8)
Loosen or tighten the other top jam nut the same number of turns. -5861
Tighten the bottom nuts back up against the top nuts on the carriage chain anchor bolts to 80 - 90 ft. -lbs. (108 - 1 22 Nm) torque. (9)
Fig. 5A-16
Adjusting Forks
Resle
5A-1 1 REMOVING THE LIFT CARRIAGE (1 ) Move the Forklift to a work area where there is enough room to back the machine away from the lift carriage after the lift carriage has been removed.
(2) Operate the control lever until the inner rail is raised high enough to put a 4 by 4" block under the back (heel) of the pallet forks.
(3)
Remove the carriage chains (See Paragraph 5A— 8).
(4)
Raise the inner rail until it is above the carriage rollers.
AWARNING
Raise the inner rail SLOWLY! If carriage rollers are not correctly aligned and the inner rail is raised fast injury or death may result.
(5) Back the Forklift away from the lift carriage slowly until it is completely clear of the lift carriage so that it can be serviced.
160 of 252
-5A-6-
2000 RTF Service Manual
5A-12 INSTALLING THE LIFT CARRIAGE ( 1)
Raise the inner rail of the vertical mast until it is above the carriage rollers.
(2) Move the Bobcat Forklift forward slowly until the inner rail is directly above the carriage rollers.
The inner rail of the vertical mast must be correctly aligned with the carriage rollers so that the rollers are not damaged when the inner rail is lowered.
(3) Lower the inner rail of the vertical mast slowly until the inner rail comes in contact with the top carriage rollers.
NOTE:
Be sure the rollers are aligned with the inner rail and that the roller guards are not in the way when the inner rail is lowered.
NOTE:
Be sure the bottom roller guards do not pivot when the inner rail is lowered.
If the rollers or guards must be moved, use a tool to move them. DO NOT put hands near moving parts of the vertical
(4)
Lower the vertical mast completely.
(5)
Install the carriage chains (See Paragraph 5A — 9).
(6)
Raise the inner rail and remove the block.
Resle
mast.
5A-13 ADJUSTING THE CARRIAGE ROLLERS The tools listed will be needed to do the following procedure (Order from Clark Equipment, Central Parts Division): 1 801089 1 801090 ( 1)
Inside Spanner Tool (Caliper) Outside Spanner Tool (Caliper)
Remove the lift carriage (See Paragraph 5A— 11).
(2) Loosen the thumb screws on the inside caliper and place it between the sides of the inner rail parallel to the lift carriage. (3)
Tighten the screw only tight enough so that it does not lose its adjustment.
(4)
Move the caliper up and down the length of the inner rail to find the
narrowest point.
NOTE:
Keep the caliper parallel to the lift carriage while finding the narrowest point.
-5A-7161 of 252
2000 RTF Service Manual
(5) At the narrowest point, loosen the screw and add one shim ,020" in size between the contact point of the caliper and the inner rail, (6)
Tighten the caliper screw to prevent movement.
(7)
Remove the caliper from the inner rail.
(8)
Put the inside caliper on a flat surface.
(9) Put the outside caliper so it contacts the extreme points on the inside caliper.
Be sure the calipers are parallel to each other.
NOTE:
(10) Tighten the screw on the outside caliper.
Check all carriage rollers for wear or damage and replace any rollers that are worn or damaged.
(11)
(1 2) Put the outside caliper across the bottom set of rollers with ends of the caliper at the points on the rollers that are farthest apart.
NOTE:
The rollers are canted. Each set goes in or out toward the back of the machine.
(13) Find the number of .020" shims, if any, that are required to remove clearance between the caliper and the rollers.
remove the rollers with a pry bar or a soft hammer.
( 1 5) Add the required number of shims. Add
Resle
(14) If shimming is required,
half the shims to one side and half
to the other.
NOTE:
If an odd number of .020" shims are required, all rollers using an extra shim must be on the same side.
(16) Install the rollers with a soft hammer. (1 7) Put the outside caliper across the bottom set of rollers to check that all clearance has been removed. If more shims are required, determine the number and add them using the above procedure. (18) Do steps 1 2 thru 1 7 for the second set of carriage rollers.
IMPORTANT 162 of 252
Do not put all the shims on one side of the lift carriage.
-5A-8-
2000 RTF Service Manual
(19) Check the alignment of the carriage rollers. Place the edge of the carpenter's square in alignment with the back edge of the bottom carriage roller on one side of the lift carriage and the front edge of the second set roller (the next roller above it). Using a machinist's rule, measure the distance between the carpenter's square and the top fork bar at several points to be sure the square is parallel to the fork bar.
(20) If the square is not parallel with the top fork bar, align the two carriage rollers.
(a)
Put the square in the parallel position with the top fork bar,
(b) If there is a gap between the square and the second set roller, remove the number of shims equal to that gap from the bottom roller. Install those shims behind the bottom roller on the opposite side of the upright.
(c) If the gap is between the square and the bottom roller, remove the number of shims equal to that gap from the bottom roller on the opposite of the upright. Install those shims behind the bottom roller being checked.
(d) Move the opposite side of the upright and do steps a thru c on the other rollers.
(a) Place a straight edge along the centers of the bottom set roller and the second set roller.
Resle
(21) Align the top set of rollers.
(b) One .020" shim should fit between the straight edge and the top roller. If the gap is greater than the width Of one shim, remove the top roller and add the necessary number of shims. Then replace the roller.
(c) Move to the opposite side of the upright and do steps a and b on the other top roller.
NOTE:
The top roller set will have an additional .040" of clearance when adjustment and alignment is complete. When the vertical mast is lifted fully up, the top roller set extends out of the inner rail. The additional clearance makes re-entry of the rollers into the inner rail when the mast is lowered easier.
(22) Install the lift carriage on the vertical mast (See Paragraph 5A— 1 2). Check for correct operation of the vertical mast.
-5A-9163 of 252
2000 RTF Service Manual
5 A— 14 PALLET FORKS
AWARNING
DO NOT exceed rated operating capacity of the Bobcat Forklift.
5A — 14.1 Installing the Pallet Forks (1)
Move the pallet fork lock lever up (Fig. 5A— 17, Item 1).
Align the bottom of the pallet fork with the notch (Fig. 5A— 1 8, Item 1 ) on the lower bar on the lift carriage and put the pallet fork (Fig. 5A— 1 8, Item 2) on the upper bar of the lift carriage. (2)
(3)
Fig. 5A-17
Moving Fork Lock Levers
Lower the pallet fork against the lift carriage (Fig. 5A— 1 8, Item 3).
Slide the pallet fork to the correct position on the lift carriage for the load being carried. The load should be centered and forks should be near the outside edges. (4)
Put the fork lock lever into lock position to lock the fork securely into the notches (Fig. 5A — 1 7, Item 2) along the top bar of the lift carriage.
(5)
(6)
Repeat steps 1 thru 6 for the other pallet fork.
!1 )
Resle
5A— 14.2 Removing the Pallet Forks
Move the pallet fork lock lever up (Fig. 5A— 1 7, Item 1 ).
(2)
Slide the pallet fork (Fig. 5A— 1 8, Item 2) along the pallet fork frame to the point as which it is aligned with the notch (Fig. 5A— 1 8, Item 1 ) in the bottom brace of the pallet fork frame. (3)
Tilt the pallet fork up and lift it off of the lift carriage (Fig. 5A — 1 8, Item 3).
(4)
Repeat steps 1 thru 3 for the other pallet fork.
5750
Fig. 5A-18
Pallet Fork
5A— 14.3 Adjusting the Pallet Forks ( 1)
Move the fork lock lever up (Fig. 5 A — 17, Item 1).
(2) Slide the fork (Fig. 5A — 18, Item 2) to the correct position on the lift carriage (Fig. 5A— 18, Item 3) for the load being carried. The load should be centered on the pallet forks and the forks should be near the outside edges of the load. (3) Push the fork lock lever down into lock position to lock the fork securely into the notches (Fig. 5A— 1 7, Item 2) on the top bar of the lift carriage. (4)
Repeat steps 1 thru 3 for the other fork.
-5A-10164 of 252
2000 RTF Service Manual
.
ELECTRICAL SYSTEM
Paragraph Number
ALTERNATOR
Page Number
....... .......
BACK-UP ALARM CHECKING THE BATTERIES DESCRIPTION NEUTRAL START SAFETY SWITCH . REPLACING THE BATTERIES SERVICING THE ELECTRICAL SYSTEM STARTER TROUBLESHOOTING THE ELECTRICAL SYSTEM WIRING HARNESS DIODES
6-8 6-10 6-4 6-1 6-7 6-5
6-5 6-11 6-3 6-1 6-4 6-3
6-2 6-9
6-2 6-8
6-3 6-6
6-3 6-4
........
A WARNING
165 of 252
Resle
ELECTRICAL SYSTEM
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
2000 RTF Service Manual
Resle 166 of 252
ENGINE WIRING DIAGRAM (6566677) 2000 RTF Starting at S/N 15001 (Printed May 1983)
64A
tr
40R
40R
30F
60B
36
41A -12C
>60
31P 21S
-35H
-31P 21S
w
Dealer
Copy
Not --
Resle for
-14R -35H -36T-
_
NO NO
—
O
BATT.
28B
Q-
36T -32T
1A Printed in U.
167 of 252
168 of 252
Dealer
Copy
Not --
Resle for
ENGINE WIRING DIAGRAM PARTS LEGEND
WIRE LEGEND #'s 36 28 ID 14R 21 36T 40R 41A IDA 66 35H 64 31P 10B 60 32TF 30F 64A 60B 21R 1C 21S 28S 32T IB 14F 1 1A 28B 23F OF 0 12C
6566677
COLOR Purple Lt. Blue/Black Red Lt. Green/White White/Orange
Purple/White Black Pink Red/Black Orange/Green
Yellow/Brown Orange/Dk. Blue
Yellow/Green Black Black Yellow/Black Black Orange/Dk. Blue Black White Red White/Lt. Green Lt. Blue/Yellow Yellow/Black Red Lt. Green Red Red Lt. Blue/Orange White/Black Cable Black Orange
(5-83MM
169 of 252
GAUGE 16 16 12 12 16 16 16 16 12 16 16 16 16 12 16 16 16 16 16 16 12 12 16 16 12 16 1 8 8 16 4 4 12
Harness Connectors Chassis Power (Fused & Switched)
O Horn Switch 0 Horn Neutral Start/Back-Up Alarm Switch
© Fuel Shut-Off Hydraulic Filter Pressure Switch
O Hydraulic Oil Temperature Switch Engine Oil Pressure Switch
Starter
O Glow Plugs © Engine Coolant Temperature O Alternator 0 Diode (2| © Glow Plug Relay © Start Relay 0 Battery © Engine Ground © Frame Ground 0Fuel Sender 0Tail Light Connector (Opt.)
•
Tee splice
O
Butt splice
Resle for
ÿ/bobcat
Resle 170 of 252
OPERATOR CAB WIRING DIAGRAM (6566678) 2000 RTF Starting at S/N 15001 (Printed May 1983)
Q yO
\
© - 46L
Dealer
Copy
-
Not --
30A
Resle for
40FR
W HL B,
171 of 252
0®©°
E-1515
Printed in U.S.A.
172 of 252
Dealer
Copy
Not --
Resle for
OPERATOR CAB WIRING DIAGRAM PARTS LEGEND
WIRE LEGEND #'s 36 28 ID 14R 21 36T 40R 41A IDA 66 35H 64 31P 10B 40FL 40FR 30T 30G 30 30A 32TF 63 12B
COLOR Purple Lt. Blue/Black Red Lt. Green/White White/Orange Purple/White
Black Pink Red/Black Orange/Green Yellow/Brown Orange/Dk. Blue Yellow/Green Black Black Black Black Black Black Black Yellow/Black Orange/Black Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange
12D 12HS
12E 12
12H 12A 12L 12T 12F 46 42FL
Brown Dk. Blue Dk. Blue Pink Dk. Blue/White
42FR 41 42R 19L 19F 19W 32 19S 49V 49T 49F 46R 46L 63A
6566678
Red/White Red/White Red/White Yellow/Black Red/White Gray Gray Gray Brown
Brown Orange/Black
(5-83MM
173 of 252
GAUGE 16 16 12 16 16 16 16 16 12 16 16 16 16 12 16 16 18 18 18 18 16 16 16 16 16 16 16 16 18 18 18 18 16 16 16 16 16 16 18 18 18 16 18 18 18 16 16 16
Harness Connector Rear Wiper (Opt.) Back-Up Alarm
Rear Lamp Tail Lamp
Accessories (Fused & Switched) Left Flasher Lamp (Opt.) Left Front Lamp Front Wiper Flasher (Opt.) Right Front Lamp Right Flasher Lamp (Opt.) Engine Temperature Gauge
Fuel Gauge Light Switch Wiper Switch
© © "Trans" Warning Lamp © "Eng" Warning Lamp © Accessory Switch (Opt.) 0 Fuse (Accessory) © Fuse (Ignition) Voltmeter Ignition Switch
Hourmeter
Shut-Down Module (Opt.) Time Delay Switch Operator Cab Ground Tee splice O Butt splice
•
Resle
w bobcat
Resle 174 of 252
6 ELECTRICAL SYSTEM 6-1 DESCRIPTION The Bobcat Forklift has a 12 volt, negative ground electrical system. There are 2 main circuits. (1) The charging circuit has an alternator (with built-in regulator), a voltmeter and 2 batteries connected in parallel.
(2) The starting circuit has a starter motor, solenoids and other parts required to start the engine.
The electrical system is protected by 2 fuses installed in the dash panel. Fuses (Fig. 6 — 1, Items 4 and 5) protect the electrical system from an overload.
IMPORTANT
C-2743
Fig. 6-1 Dash Panel
If a fuse fails, find the reason for the overload before starting the engine again. Look for a short in the electrical system.
6—1.1 Dash Panel The dash panel has the following instruments (Fig. 6—1): (1 )
HOURMETER - Records total operating hours of the Forklift.
(2)
KEY SWITCFI
For starting and stopping the engine and pre-heat
Resle
-
operation. (3)
VOLTMETER - Shows condition of the battery and rate of charge.
(4) FUSE (Accessories) electrical overload.
(5)
- Protects the
accessory electrical system from
FUSE (Ignition) - Protects the electrical system from electrical overload.
(6) ENGINE WARNING LIGHT the light comes "ON".
- Warns of
low oil pressure. Stop the engine if
(7) TRANSMISSION WARNING LIGHT - Warns of high oil temperature or plugged left hand filter. Stop the engine if the light comes "ON".
(8)
WIPER SWITCH - Controls the windshield wiper.
(9)
LIGHT SWITCH - Controls work and travel lights and dash panel lights.
(10) FUEL GAUGE (11)
- Shows amount of fuel
in the tank.
ENGINE TEMPERATURE GAUGE - Shows engine coolant temperature.
6—1.2 Wiring Diagrams
The three-page fold-outs are wiring diagrams for the operator cab electrical circuitry and engine electrical circuitry.
-6 — 1175 of 252
2000 RTF Service Manual
6-2 SERVICING THE ELECTRICAL SYSTEM 6
— 2.1 Cautions to be Taken in Use of the Alternator ( 1)
Do Not reverse battery connections. This is a negative ground system only.
(2)
Connect batteries correctly.
(3)
Do Not polarize the alternator.
(4)
Do Not ground any wires from the alternator.
(5)
Do Not operate the engine with the batteries disconnected from the
system.
(6) Disconnect at least one battery cable (ground terminal) if a battery charge is used.
6
— 2.2 General Servicing
ik WARNING
NOTE:
Lead-acid batteries contain sulfuric acid which will damage the eyes or skin on contact. Always wear goggles to avoid acid in the eyes, wash immediately with much clean water and get medical attention. Wear rubber gloves and protective clothing to keep acid off the skin. If acid contacts the skin, wash off immediately with clean water.
Use a battery cable remover when removing battery cables.
(2)
Clean the battery terminals with a battery terminal cleaner.
(3)
Cover the terminals with grease to reduce corrosion.
(4)
Check the tension of the alternator belt (See Paragraph 6 — 8.2).
(5)
Make sure all wire connections are tight.
(6)
Check for broken or open wires or shorts.
Resle
(1 ) Check to see that battery cables are clean and tight. Check the water level of the batteries (unless the machine is equipped with maintenance-free batteries). Remove acid or corrosion from the batteries and cables with sodium bicarbonate (baking soda) and water solution.
NOTE: The "ENG" warning light will come on "ON" when the key switch is turned "ON". When the engine is started the light must go "OFF". If it does not go off, stop the engine and find the problem. NOTE: The "TRANS" warning light is on a time delay switch and will go "OFF" in a few seconds. If the light does not go off within a few seconds after the engine is started, stop the engine and find the problem. 6 — 2.3 Charging the Batteries
Batteries are normally charged by the machine's charging system. In order to charge batteries with a battery charger, See the Clark Battery Manual No. 6566047, page 1 1. 176 of 252
-6-2-
2000 RTF Service Manual
6-3 TROUBLESHOOTING THE ELECTRICAL SYSTEM The following troubleshooting chart gives information about the problems most often found.
CAUSE
PROBLEM Battery has a low charge.
1, 2, 3, 4, 5, 6
Battery has an overcharge.
3, 6
Starter will not turn the engine.
KEY TO CORRECT THE CAUSE 1. 2.
3. 4. 5. 6. 7. 8. 9.
7, 8, 9
Alternator belt loose or damaged. Battery connections are poor. Batteries are not working correctly. Electrical system has incorrect ground. Alternator is not working correctly. Regulator is not working correctly. Engine seizure. Starter is not working correctly. Wiring or solenoids are not working correctly.
6-4 CHECKING THE BATTERIES
IMPORTANT c
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from the battery. Make "jump" start connections as recommended in this manual. When connecting extra battery for "jump" start always make the last connection (negative cable) to the engine (never to the battery). When removing the "jump" start cables, always remove the negative cable from the engine first. Never charge a frozen
The Bobcat Forklift has 2 parallel connected batteries installed in the engine compartment (Fig. 6 — 2). i-5879
There are 2 ways of checking the batteries. (1 ) Charge the batteries (See Clark Battery Manual No. 6566047 [8-80], Page 11). Check the battery with hydrometer. (Clark Battery Manual, Page 5). If the
Fig. 6-2
Location of Batteries
batteries take a charge they are probably good. Do the Voltmeter test Procedure (Clark Battery Manual, Page 6 and the Load Test Procedure, Page 7).
(2)
6-5 REPLACING THE BATTERIES (1) Remove battery cables negative ( — ) cable first (Fig. 6 — 2, Item 1). Remember the position of positive ( + ) terminal and negative ( — ) terminal so that you can connect cables correctly after replacement. (2) Remove the battery holddown clamps (Fig. 6 — 2, Item 2). Remove batteries from the engine compartment.
(3)
NOTE:
Clean terminals of the new batteries and clean the cable clamps. DO NOT touch the battery terminals with any metal.
(4) Install the batteries in the correct location and install battery holddown clamps. (5)
Install and tighten battery cables. Connect ground negative ( — ) cable last
to prevent sparks.
NOTE:
If one battery needs replacement, you must replace both batteries. -6-3-
177 of 252
2000 RTF Service Manual
Resle
battery.
1. 2. 3. 4. 5.
6-6 WIRING HARNESS DIODES 6
— 6.1 Description
There are 2 diodes installed in the wiring harness in the engine compartment. They are installed on the wires in the harnesses near the connectors. A diode is like and electrical check valve. It lets electric current flow in one direction but not in the other direction.
Wiring Harness Diode Lead Unsoldered Ohmmeter Black Band Around Diode Electrical Symbol
6 — 6.2 Checking the Diodes (Fig. 6 — 3) If the alternator is not working correctly, the diode in the wiring harness near the alternator may need to be replaced. If the starter operates when the key switch is turned to the preheat position, the diode in the wiring harness near the glow plug relay may need to be replaced. Check the diodes for correct operation. (1 )
Find the diode in the wiring harness (Item 1 ).
(2)
Remove tubing around the diode.
(3)
Remove the solder from one diode lead (Item 2).
NOTE:
A-2847
Fig. 6-3
Checking the Diodes
Use a pliers as a heat sink to prevent damage to the diode when removing solder.
(4) Connect an ohmmeter between diode lead and the wire that you disconnected. Measure the resistance with ohmmeter (Item 3). (5)
Reverse the ohmmeter leads and measure resistance again.
(6) If resistance in one direction is not at least 1 0 times greater than resistance in the other direction, the diode is defective. (7)
Solder diode lead (Item 2) or replace diode as required.
(8)
Wrap solder connections with electrical tape to prevent short circuits.
6 — 6.3 Replacing the Diodes (Fig. 6 — 3) Reference No. (Item 5) is the electrical symbol for a diode. There is a black band around one side of the diode (Item 4). In the electrical symbol, the arrow points towards the black band.
Resle
NOTE:
(1) Remember how the defective diodes are removed so that new diodes can be installed correctly. Diodes installed backwards will not work and may cause damage to the system. (2)
Unsolder defective diodes and remove them from the wiring harness.
(3)
Install new diodes by soldering them in place.
(4)
Check the new diodes.
(5)
If new diodes are good, carefully wrap all connections with electrical tape circuits.
to prevent short
6-7 NEUTRAL START SAFETY SWITCH
The neutral start safety switch will prevent the machine from being started unless the foot pedal is in neutral.
NOTE:
—
See Section 3, Paragraph 3 4.8, Page 3 — 9 for the correct procedure for adjusting the neutral switch.
6 — 7.1 Checking the Neutral Start Safety Switch (1) Move the foot pedal so that line marked on the neutral start safety switch is 1/2" away from switch body.
178 of 252
-6-4-
2000 RTF Service Manual
(2) Try to start the engine. The engine should not start.
Let the foot pedal come back the center position. Make sure that line marked on shaft is within 1/32" of switch body. If line is not within 1/32" of switch body see paragraph 3 — 4.8, page 3 — 9. (3)
to
(4) Try to start the engine. The engine should start now.
1/10ÿÿ8-5879 Fig. 6-4
Fig. 6
Removing Shield
—5
Checking Belt Tension
6-8 ALTERNATOR 6
— 8.1 Description
The alternator is an electrical device that makes electric current to charge the machine's batteries. The alternator has a built-in voltage regulator.
The alternator is turned by a belt from the engine.
6
— 8.2 Adjusting or Replacing the Alternator Belt (1 )
Stop the engine. Remove shield (Fig. 6 — 4).
(2)
Loosen alternator adjusting bolt (Fig. 6 — 5, Item 1).
(3)
Loosen the alternator mounting bolt (Fig. 6 — 5, Item 2).
(4)
Remove or replace the drive belt as needed.
Resle
(5) Move the alternator to give the belt .31" (7,87 mm) deflection with 14.3 pounds (6,49 kg) of force, between the sheaves. (6) Tighten the adjusting bolt and mounting bolt when the belt is at the correct tension. (7)
6
Install the shield.
— 8.3 Checking Alternator Wiring (1)
Turn the key switch "ON".
(2)
Connect a voltmeter between
ground and:
No. 1 alternator terminal (Fig. 6 — 6, Item 1 ).
(a)
(b) No. (Item 2).
(c)
2 alternator terminal
Battery terminal (Item 3).
®
No. 1 Termi No. 2 Terminal 3. Battery Terminal 4. Test Hole 1.
j
2.
(3) If any of these tests show zero voltage, the wiring needs repair.
v*vÿXj||i |J
Fig. 6
—6
X.
)f
B-21 13
Alternator
-6-5179 of 252
/-'jjgjBWv
2000 RTF Service Manual
(4)
Find the problem in wiring and make repair.
(5)
Check voltage again.
6 — 8.4 Checking Alternator Output
Lift the machine and put blocks under the frame (See Paragraph 1—2, Page 1 — 1) so that there is no danger of the machine moving during service. Failure to obey warnings may cause injury or death.
(1)
Disconnect negative battery cable.
(2) Remove wire from "BAT" terminal on alternator and fasten it to ( — ) connector of an ammeter. Fasten (+) connector of the ammeter to battery
terminal of alternator. (3)
Connect battery cable again.
(4) Disconnect the wire from the fuel solenoid and turn the engine with the starter for approximately 30 seconds to cause a discharge of the battery. (5) Connect the wire to the fuel solenoid and start engine and run at full throttle. The ammeter reading must be within 10 amps of rated amperage (marked on alternator case). (6) If reading is correct, alternator is good. If reading is more or less than 10 amps of rated amperage, check the regulator.
6 — 8.5 Checking the Regulator Connect ammeter as in paragraph 6 — 8.4.
Resle
(1)
Disconnect the wire from the fuel solenoid and turn engine with starter for 1 5 seconds at a time to cause a discharge of the battery.
(2)
(3)
Connect the wire to the fuel solenoid, start engine and run at full throttle.
(4)
Put a small screwdriver in test hole (Fig. 6 — 6, Item 4).
(5) If ammeter reading is within 10 amps of rated amperage (37 amps), the regulator probably has a defect. If ammeter is not within 10 amps of 37 amp., check the diode trio, rectifier, stator or rotor. See below for these checks.
6
— 8.6 Removing the Alternator (1)
Disconnect negative battery cables.
(2)
Disconnect wires from alternator.
(3)
Remove adjustment bracket bolt.
(4)
Remove two bolts that hold alternator and remove alternator.
6 — 8.7 Disassembling the Alternator (Fig. 6 — 7) (1 )
Put a mark across each half of alternator case to help in correct assembly.
(2)
Remove sheave from shaft (Item 1). 180 of 252
-6-6-
2000 RTF Service Manual
Sheave Bolt Rotor Stator Diode Trio Rectifier Regulator
Fig. 6-7
(3)
Disassembling the Alternator
Remove four bolts that hold case together (Item 2).
(4) Use a screwdriver to move halves apart. Slide the rotor out of housing (Item 3). (5) Remove nuts that hold (Item 4).
(6)
6
"Jill
three stator wires to the housing. Remove stator
iLJ-fe-- .7
Disconnect diode trio (Item 5).
— 8.8 Checking the Rotor (Fig. 6 — 8). (1)
Resle
1. 2. 3. 4. 5. 6. 7.
a A-1 8 57
Connect an ohmmeter between one slip ring and shaft. There must be
maximum resistance.
Fig. 6 — 8
Checking Rotor Coil Wires
(2) Connect an ohmmeter between both slip rings. Resistance must be between 2.4 ohms and 3.0 ohms. If not, there is a defect in rotor.
6 — 8.9 Checking the Stator (Fig. 6 — 9) (1) Connect a test light between the center wire connection and one of the outside wire connections. If the light does not come on, there is a defect in the
stator. (2) Connect a test light between the center wire connection and the other outside connection. If the light does not come on, there is a defect in stator.
Connect a test light between one of the wire connections and the frame of the stator. If the light comes on, there is a defect in the stator.
B-2108
(3)
-6-7181 of 252
Fig. 6-9
Checking Stator Coil Wires
2000 RTF Service Manual
6 — 8.10 Checking Diode Trio (Fig. 6-10)
(1) Connect a test light between the single connection and one of the three connections. Connect the tester the opposite way. The light must come on when connected one way, but not then connected the other way.
IMPORTANT
1. 2.
A-2382
Fig. 6
Checking Diode Trio
Do not use voltage that is more than circuit voltage to check the diode trio or rectifier on the alternator.
(2)
Insulated Heat Sink Grounded Heat Sink
B-2 1 0 1
B-2 1 02
Fig. 6-11
Checking Rectifit
Fig. 6—12
Insulation Washers & Spacers
Do step (1 ) for the other two diodes.
(3) Connect a test light between the center connection and each outside connection (one at a time). If the light comes on, there is a defect in the diode trio.
6 — 8.11 Checking Rectifier (Fig. 6—11) (1)
Remove rectifier from alternator.
(2)
Tighten three nuts on the connections.
(4) Connect a test light between the same connection and the grounded heatsink (Item 2). Connect the tester the opposite way. The light must come on when connected one way but not when connected the other way.
Resle
(3) Connect test light between one connection and insulated heatsink (Item 1 ). Connect the tester the opposite way. The light must come on when connected one way but not when connected the other way.
B-2 1 28
Do steps (3) and (4) on both of the other connections. If any tests are bad, replace rectifier. (5)
6 — 8.12 Assembling and Installing the Alternator Assembly and installation is reverse of removal and disassembly.
If the regulator is removed, be sure the two insulation washers and spacers are in good condition (Fig. 6—12). To install the rotor, put a piece of straight wire through the housing to hold the brushes in place (Fig. 6—13).
6-9 STARTER 6 — 9.1 Description The starter is a heavy duty electric motor that starts the engine when the key switch is turned to the START position.
182 of 252
-6-8-
B-2097
Fig. 6-13
Holding Brushes
2000 RTF Service Manual
6 — 9.2 Checking Starter (Fig. 6—14) (1 ) Lift the Bobcat Forklift and put blocks under the frame so that there is no danger of the machine falling and causing personal injury (See Paragraph 1 —2, Page 1—1 for the correct procedure).
(2) Keep ignition switch off. Be sure the battery has full charge and the connections are clean and tight. (3) Connect a jumper wire between small terminal (Item 3) and battery terminal (Item 2) of the solenoid. If the starter turns, but does not turn the engine, the defect is in the starter drive. If the starter does not turn, continue with step below. (4) Connect the jumper wire between battery terminal (Item 2) and lower terminal (Item 4). If the starter turns rapidly, the defect is in the solenoid. If starter does not turn, the defect is in the starter.
6 — 9.3 Removing Starter (1)
Disconnect negative battery cable.
(2)
Disconnect wires from starter connections.
(3)
Remove the two bolts that hold the starter in place, and remove starter.
Jumper Wire Battery Terminal Small Terminal Lower Terminal Solenoid Cranking Motor
Fig. 6-14
A-1 991
Checking Starter
6 — 9.4 Disassembling the Starter (Fig. 6—15) (1 )
Remove the connector link between the solenoid and the starter.
(2) Remove nuts and washers that fasten the solenoid to the drive end of housing. (3) Remove the main part of the solenoid (Item 1). Remove the plunger (Item 3) and the spring (Item 2) by lifting it from the top of the shift fork (Item 4).
The plunger (Item 3) must also be replaced if the main part of the solenoid is replaced.
Resle
NOTE:
(4) ' Remove bolt (Item 5) from the housing in the shift fork pivot. (5)
Remove the bolts from end
cap (Item 6) and starter frame (Item 7). (6) Remove shaft fork (Item 4) from the starter frame. (7) Remove shim washer (Item 8) from shaft armature at commutator end. Remove he armature (Item 9) complete with internal thrustwasher (Item 10) and drive assembly (Item 11), through the drive end of the starter frame.
(8) Remove thrustwasher (Item 10) from the commutator end of the armature shaft. (9) Remove drive stop ring (Item 12), thrust collar (Item 13), and slide drive assembly (Item 11) off
the armature shaft.
183 of 252
®r~' 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1 1. 12. 13.
Solenoid Spring Plunger Shift Fork Bolt End Cap
Frame Shim Washer Armature Internal Thrustwasher Drive Assembly Drive Stop Ring Thrust Collar
Fig. 6-15
B-1 192
Disassembling the Starter
-6-9-
2000 RTF Service Manual
6 — 9.5 Cleaning and Inspecting the Starter
DO NOT use solvent to clean the drive because solvent will remove lubricant and cause the drive to slip.
NOTE:
(1) Use a brush and compressed air to clean the drive, field coils, armature, commutator, front plate and rear housing. Wash all other parts in solvent and let
dry.
(2)
Inspect the armature for
broken or
burned insulation and loose
connections. (3)
Check the armature for open and ground circuits.
(4) Check the armature shaft and bearings for damage and wear. If the commutator is rough, make smooth.
(5) Check brush holders for broken spring and for broken insulation. Make replacement of the brushes if wear is more than 5/1 6 inch. (8.0 mm).
(6)
Check brush spring tension. Make replacement if springs are weak.
(7) Inspect the field coils for burned or broken insulation and electrical continuity. Check field brush connections and wire insulation. A brush kit is
available. (8) Check the starter drive gear for tooth wear. The starter drive gear must engage more than 1/2 the depth of ring gear teeth on flywheel.
Resle
6 — 9.6 Replacing the Brushes (1) Cut the two brush wires at the connection post. Use a file or hacksaw to make a groove in the top of the post deep enough to hold new brush wires. Be sure the insulation is on the new brush wires. Solder the brush wires into the
groove.
(2) Cut the other brush wires about 1/4 inch (6.3 mm) from the joint of the field winding. Solder the new brush wires to the ends of the original brush wires. Be sure insulation is over solder connections.
6
— 9.7 Assembling the Starter (Fig. 6—15) (1 ) Put a small amount of lubricant on the armature shaft splines. Install the drive assembly on armature shaft, install the thrust collar and stop ring.
(2)
Install shim washer (Item 8) on commutator end of the armature shaft.
(3) Install the brushes in the end plate and fasten the end plate to the starter frame with screws.
Put a small amount of lubricant on internal thrustwasher (Item 10), and install the armature and drive assembly through the drive end of starter frame. Install the thrust plate, shim washer and cotter pin on the armature shaft. Check the end play of the armature. Add or remove shims for correct end play. (4)
184 of 252
-6-10-
2000 RTF Service Manual
(5) Install rubber seal, plunger and return spring assembly on the top of the shift fork. Put the shift fork on the drive assembly.
(6)
Install the drive housing on the starter frame and install washers and
(7)
Put the pivot pin into the housing and shift fork and tighten the
(8)
Install rubber sealing block between the drive housing and the frame.
nuts.
nut.
Put main part of solenoid over the plunger assembly and into the drive housing. Install washers and nuts.
(9)
(10) Install the
link between solenoid and starter.
6-10 BACK-UP ALARM The Bobcat Forklift is equipped with a back-up alarm which sounds when the key switch is in the "ON" position and the machine is in reverse drive.
If the back-up alarm does not sound when the machine is in reverse: ( 1 ) Use a 1 2 volt test light to check the switch in the electrical circuitry to be sure it is working correctly.
(2)
Check for correct wiring of the alarm in the electrical
(3)
Connect a 1 2 volt power source to the alarm unit to check it for correct
system.
Resle
operation.
I
185 of 252
-6-11-
2000 RTF Service Manual
Resle 186 of 252
ENGINE SERVICE
....... ........ ........ ......... Paragraph Number
CHECKS AND ADJUSTMENTS COOLING SYSTEM CYLINDER HEAD ENGINE AND ATTACHING PARTS FLYWHEEL FUEL SYSTEM AND TIMING
LUBRICATION SYSTEM RECONDITIONING THE ENGINE TIMING CASE AND GEARS TROUBLESHOOTING
....
7-2 7-9 7-5 7-4 7-10 7-3 7-8 7-6 7-7 7-1
Page
Number
7-3
7-43 7-16 7-11 7-45 7-4 7-38 7-23 7-32 7-1
ENGINE
SERVICE
Resle
Notes: Worldwide Parts Source Email:
[email protected] Phone: 269 673 2313
Instructions are necessary before doing service on forklift. See warnings and instructions both at beginning and throughout this manual. After doing service or making repair or adjustment, always check function of machine.
A WARNING
Safety glasses or goggles are always needed for eye protection from electric arcs from shorts or welding, battery acid, compressed springs, fluids under pressure, and flying debris or loose material when engines are on or tools are used. Failure to obey warnings can cause injury or death.
2000 RTF Service Manual 187 of 252
Resle 188 of 252
7 ENGINE SERVICE 7-1 TROUBLESHOOTING
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM
CAUSE 1, 2, 3, 4
Engine will not start.
5, 6, 7, 8, 9, 10, 1 1, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult to start.
5, 7, 8, 9, 10, 1 1, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33
No power from engine.
8, 9, 10, 1 1, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33
Engine is mis-firing.
8, 9, 10, 12, 13, 14, 18, 19, 20, 25, 26, 28, 29, 31, 32, 33
Too much fuel consumption.
1 1, 13, 14, 18, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33
Too much oil consumption.
4, 31, 33, 34, 54, 55
Black exhaust.
1 1, 13, 14, 18, 19, 20, 22, 24, 25, 28, 29, 31, 32, 33
Blue/white exhaust.
4, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56
Low oil pressure
4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Engine knocking.
9, 14, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Engine running rough.
7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration.
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 48, 49
High oil pressure.
4, 38, 41
Overheating.
1 1, 13, 14, 18, 19, 24, 25, 45, 47, 50, 51, 52, 53, 54, 57
Too much crankcase pressure.
25, 31, 33, 34, 45
Poor compression.
1 1, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Start and stop.
10, 11, 12
-7-1189 of 252
Resle
Slow cranking speed.
2000 RTF Service Manual
7-1 TROUBLESHOOTING (Cont'd)
KEY TO CORRECT THE CAUSE Battery capacity low.
30.
Incorrect high pressure tubeiines.
2.
Bad electrical connection.
31 .
Worn cylinder bores.
3.
Faulty starter motor.
32.
Worn valves and seats.
4.
Incorrect grade of oil.
33.
Broken, worn or sticking piston rings.
5.
Low cranking speed.
34.
Worn valve stems and guides.
6.
Fuel tank empty.
35.
Overly full air cleaner.
7.
Faulty stop control operation.
36.
Worn or damaged bearings.
8.
Plugged fuel line.
37.
Not enough oil in the oil pan.
9.
Faulty fuel lift pump.
38.
Gauge is not correct.
10.
Plugged fuel filter.
39.
Oil pump worn.
1 1.
Restriction in the air cleaner.
40.
Pressure relief valve is open.
41 .
Pressure relief valve is sticking closed.
12. Air in the fuel system.
13.
Faulty fuel injection pump.
42.
Broken relief valve spring.
14.
Faulty fuel injectors.
43.
Faulty suction pipe.
1 5.
Incorrect use of the glow plugs.
44.
Plugged oil filter.
16.
Faulty glow plug(s).
45.
Piston seizure.
1 7.
Broken fuel injection pump drive.
46.
Incorrect piston height.
18.
Incorrect fuel injection pump timing.
47.
Damaged fan.
1 9.
Incorrect valve timing.
48.
Faulty engine mounting.
20.
Poor compression.
49.
Faulty thermostat.
21 .
Plugged fuel tank vent.
50.
Restriction in the water jacket.
22.
Incorrect type or grade of fuel.
51 .
Loose fan belt.
23.
Sticking or restricted throttle.
52.
Plugged radiator.
24.
Exhaust pipe restriction.
53.
Faulty water pump.
25.
Cylinder head gasket leaking.
54.
Plugged breather pipe.
26.
Overheating.
55.
Valve stem seals damaged.
27.
Cold running.
56.
Coolant level is low.
28.
Incorrect valve tappet adjustment.
57.
Plugged oil pump pipe strainer.
29.
Sticking valves.
58.
Broken valve spring.
-7-2190 of 252
Resle
1.
2000 RTF Service Manual
7-2 CHECKS & ADJUSTMENTS 7 — 2.1 Oil Pressure Engine oil pressure is good if the red warning light on the dash panel is not illuminated. To check the operation of the light, turn the ignition switch to the "ON" position. The warning light must be illuminated. Minimum oil pump pressure is 30 PSI.
To check the operation of the light, disconnect the wire from the sender. Ground the wire to the frame and the light must come "ON". If it does not, check the light bulb. 8-5787
Fig. 7-1
Valve Adjustment
7 — 2.2 Valve Clearance
Make sure the valve adjustment is done with the engine stopped and cold. Put the size feeler gauge between the rocker arm and the valve stem and turn the adjustment bolt in or out to get the correct clearance (Fig. 7— 1 ). correct
The correct clearance for the intake and exhaust valves is 0.01 2" (0,30 mm) cold (Fig. 7-2).
0.012 in. (0,30 mm) cold
Use the following procedure to set the valves: (a) With the rocker arms rocking on No. 4 cylinder, set the clearance at No. 1 cylinder.
8-4123
Fig. 7-2
Valve Clearance
(b) With the rocker arms rocking on No. 2 cylinder, set the clearance at No. 3 cylinder.
Resle
(c) With the rocker arms rocking on No. 1 cylinder, set the clearance at No. 4 cylinder.
(d) With the rocker arms rocking on No. 3 cylinder, set the clearance at No. 2 cylinder.
7 — 2.3 Check Engine Compression The tool listed will be needed to do the following procedure:
MEL-1 06300
—
Compression Test Kit
The engine must be at operating temperature and turning at about 175 RPM (cranking RPM). The compression must be between 300 and 500 PSI (2069 - 3448 kPa) with no more than 50 PSI (345 kPa) difference between the cylinders. Check each cylinder as shown in figure 7 — 3. Remove glow plug. Install the adapter and connect the gauge.
B-593 1
Fig. 7-3
Compression Test
Notes: Worldwide Parts Source Email:
[email protected] -7-3191 of 252
Phone: 269 673 2313
2000 RTF Service Manual
7-3 FUEL SYSTEM AND TIMING
A distributor type fuel injection pump is located at the rear of the timing case and is driven by the fuel pump gear in the timing case.
A water trap fuel filter is located between the fuel tank and the injection pump on the left side of the engine.
The fuel injectors are positioned on the fuel injection pump side of the cylinder head. The fuel injectors use pintle type nozzles.
B-5822
Fig. 7-4 Throttle
Linkage
7 — 3.1 Fuel Injection Pump The tool listed will be needed to do the following procedure:
MEL-1 200 - Puller
The injection pump contains parts which have a very close tolerance and its operation has a direct effect on the performance of the engine.
B-5794
Removing the Fuel Injection Pump
Remove the throttle control linkage rod (Fig. 7 — 4, Item 1) from the injection pump. (1)
Fig. 7
—5
Electrical Shut-Off Wire
(2) Remove the wire from the electrical fuel shut-off at the rear of the injection pump (Fig. 7 — 5).
IMPORTANT (3)
When removing or replacing the high and low pressure tubelines from the injection pump, DO NOT bend them.
Remove the high pressure and low pressure tubelines from the injection
pump.
Notes: Worldwide Parts Source Email:
[email protected] 192 of 252
-7-4-
Phone: 269 673 2313 2000 RTF
Service Manual
Resle
IMPORTANT
Adjustment or maintenance must be done by trained personnel with correct equipment.
(4) Remove the pump support bracket at the bottom of the injection pump (Fig. 7 — 6, Item 1). (5) Remove the valve cover. Turn the engine until both valves on No. 4 cylinder are open.
IMPORTANT
B-4699
B-5790
7— 6
Fig. 7
Injection Pump Bracket
—7
Timing Gear Cover
Make sure the valves on No. 4 cylinder are both open, because this will put the key for the injection pump at the top so that the key will not fall into the timing case when the pump is removed.
(6)
Remove the two injection pump mounting nuts and washers.
(7)
Remove the cover from the timing case cover (Fig. 7 — 7).
(8)
Remove the gear nut and spring washer (Fig. 7 — 8). Fig. 7-8
Drive Gear Nut
With the injection pump supported, loosen the pump gear using the special tool (Fig. 7 — 9). (9)
NOTE:
Remove the injection pump (Fig. 7 — 10) from the engine.
Make sure that the key does not drop off the shaft and into the timing gears.
Resle
(10)
Installing the Fuel Injection Pump (1)
Make sure the keyway of the pump gear is at the top.
(2) Put the injection pump into the engine with the marks in alignment (Fig. 7-10).
B-5792
Fig. 7-9
NOTE:
Removing Drive
Make sure that the key enters the keyway of the gear.
(3) Install the spring washer and nut on the fuel pump gear (Fig. 7 — 8). Tighten the nut to 50 ft. -lbs. (69 Nm) torque.
NOTE:
If a new injection pump is installed, check the timing (See Paragraph 7-3.2).
Install the nuts and washers at the injection pump flange and tighten. Install the support bracket at the bottom of the injection pump (Fig. 7 — 6).
(4)
(5)
Install the cover on the timing case cover (Fig. 7 — 7). Fiq.
-7-5-
Notes: Worldwide Parts Source Email:
[email protected] 193 of 252
7—10
Removing Injection Pump
Phone: 269 673 2313
2000 RTF Service Manual
(6) Install the high pressure and low pressure tubelines. (7) Connect the electrical wire. Install the throttle linkage. (8)
Install the valve
(9)
Remove the air from the fuel 1—9.3,
cover,
system (See Paragraph Page 1—6).
NOTE:
Maximum Speed Setting: The maximum speed screw (Fig. 7—11, Item 1) is set by the manufacturer. Any adjustment must be done by an experienced fuel injection technician. The idle speed screw (Fig. 7 — 11, Item 2) can be adjusted to give the engine an idle RPM of 800 to 1000 RPM at normal operating
B-5805
B-5797
Fig. 7-11
Fig. 7-12
Idle Speed Adjustment
Rocker Arm Nut
uM
temperature.
7 — 3.2 Timing the Fuel Injection Pump The tool listed will be needed to do the following procedure:
4 Fig. 7-13
B-5798
B-5806
Shaft Snap Ring
Fig. 7-14
Removing Spring
Fig. 7-16
Timing Plug
MEL-1 201 - Timing Tool (1)
Remove the valve cover.
Resle
(2) Turn the engine until No. 1 piston is at TDC on the compression stroke (both valves of the No. 4 cylinder are moving).
(3) Loosen the adjusting bolt of the rocker arm on the No. 1 intake valve (Fig. 7—12).
Remove the snap ring at the end of the rocker arm shaft (Fig. 7—13) and remove the rocker arm.
A-2347
(4)
Fig. 7-15
installing Dial Indicator
(5) Remove the valve spring from the No. 1 cylinder intake valve (Fig. 7 — 14). Put the valve head on the top of the piston crown.
(6) Install a dial indicator on the top of the valve stem (Fig. 7—15). Turn the engine backward and forward a small amount to find TDC (maximum piston height) and zero the dial indicator. (7)
Remove the high pressure tubelines from the injection pump.
(8)
Remove the plug and washer at the rear of the injection pump (Fig. 7—16).
(9) Install the timing tool and dial indicator so that the plunger of the timing tool is against the pump plunger and the dial indicator reads approximately 0.08" (2,0 mm) (Fig. 7-17).
Notes: Worldwide Parts Source Email:
[email protected] -7-6194 of 252
B-5800
Fig. 7-17
Installing Timing Tool
Phone: 269 673 2313
2000 RTF Service Manual
(10) Turn the engine crankshaft slowly counterclockwise until the plunger of the timing tool reaches its maximum travel (minimum pump plunger lift) and set the dial indicator to zero.
(11) Turn the engine crankshaft clockwise until the No. 1 piston is at TDC and the dial indicator at the intake valve reads zero.
(1 2) Check the reading on the timing tool. If the dial indicator reads 0.0386 to 0.0402" (0,98 to 1 ,02 mm) plunger lift, the injection pump timing is correct.
(13) If the timing is not correct, do the following procedure: (a)
Disconnect the low pressure fuel line.
(b)
Loosen the flange nuts and the support bracket bolt.
(c) If the dial indicator reads more than 0.0402" (1,02 mm). Turn the injection pump counterclockwise (from the rear) until 0.0394" (1,0 mm) plunger movement is indicated, tighten the flange nuts. (d) If the dial indicator reads less than 0.0386" (0,98 mm), turn the injection pump clockwise (from the rear) past the 0.0394" (1 ,0 mm) and then counterclockwise to 0.0394" (1 ,0 mm), tighten the flange nuts.
(14) Turn the engine crankshaft a small amount in
each direction and back to
TDC.
( 1 5) Check the timing again (Step 1 2).
the timing tool and dial indicator.
Resle
(1 6) When the timing is correct, remove
( 1 7) Install the plug and washer. Install the high pressure tubelines and the low pressure fuel line. Tighten the pump support bracket.
(1 8) Where necessary, remove the old timing mark at the flange of the injection pump and make a new timing mark.
(19) After the timing adjustment, turn the engine to TDC in the normal direction of rotation. Remove the dial indicator and install the valve spring and rocker arm.
(20) Adjust
the rocker arm. Install the valve cover.
7 — 3.3 Fuel Injector Nozzles
When replacing the fuel injectors in the cylinder head it is important that a new copper washer is fitted between the nozzle end and cylinder head.
Notes: Worldwide Parts Source Email:
[email protected] 195 of 252
-7 — 7-
Phone: 269 673 2313
2000 RTF Service Manual
A WARNING
Washers
Diesel fuel under pressure can penetrate the skin or damage eyes. Leaks of fluids under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not
use bare hand. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical attention. B-5802
These are some of the engine problems caused by injector nozzles which are not working correctly:
Fig. 7-18
Fuel Injector Nozzle Return Line
a.
The engine is hard to start or will not start.
b.
Rough engine operation (Engine knock).
c.
The engine will not idle correctly.
d.
The engine will not have full power.
e.
The engine exhaust smoke is black, white or blue.
Remove the injector nozzles from the engine and test them only after the engine performance indicates that they may not be working correctly.
IMPORTANT
Resle
Removing the Fuel Injector Nozzles
Do not disassemble or test the injector nozzles unless you have the correct service and testing tools.
(1) Remove high pressure tubelines from the injector nozzles. (2) Remove the fuel return line from the injector nozzles (Fig.
7-18). (3) Remove the nuts from the fuel injector crossbar (Fig. 7—19) and remove the injectors from the engine (Fig. 7 — 20).
Checking the Fuel Injectors Nozzles
The tools listed will be needed to do the following procedure:
MEL-10018 MEL- 10019
A-2846
Injection Nozzle Tester Accessory Set
Fig. 7-19
Fuel Injector Nuts
Notes: Worldwide Parts Source Email:
[email protected] 196 of 252
-7-8-
Fig. 7-20
Removing Fuel Injector
Phone: 269 673 2313
2000 RTF Service Manual
( 1)
Connect the injector nozzle to the tester with the nozzle in a down position.
(2) Slowly operate the hand lever of the test pump until the injector nozzle valve opens. The pressure for a new nozzle is 1 920 PSI (1 3,238 kPa). (3)
CORRECT
WRONG
If the pressure is not correct, either clean or replace the injector nozzle.
(4) Check for inside leakage. Operate the hand lever until the pressure is almost enough to open the injector valve. Make a record of the pressure. Release the hand lever. Check the pressure decrease for six seconds. The injector nozzle is damaged if the pressure decrease is more than 740 PSI (5,162 kPa) is six seconds.
AWARNING
Fig. 7-21 Spray Pattern
Check the spray pattern of the nozzle for the following conditions (Fig.
7-21):
17 ft. -lbs. (23 Nm)
(a)
Does not come out the side of the nozzle.
(b)
Does not have drops coming from the nozzle.
(c)
Does not have a flow (solid stream) coming from the nozzle.
15 ft. -lbs. (20 Nm)
Any of the above conditions indicate damage or a dirty injector nozzle. Clean the nozzle and make the test again. Replace any injector nozzle that does not operate correctly after being cleaned.
1
// i (( U-J
LJ
VP
A-2668
Installing the Fuel Injector Nozzles
Fig. 7-22
(1)
Install a new copper washer in the cylinder head (Fig. 7 — 20, Item 1).
(2)
Install the fuel injector nozzle and install the nuts.
(3)
Tighten the nuts on the injectors to the correct torque (Fig. 7
Resle
(5)
A-2621
Keep away from fuel coming from the nozzles. Wear eye protection.
Torque Specification
— 22) in half
step sequence.
(4) Install the fuel tubelines and tighten the fittings to 5 ft. -lbs. (6,8 Nm) torque, then 1 0 ft. -lbs. (1 3,6 Nm) torque and the final step to 1 5 ft. -lbs. (20,3 Nm) torque (Fig. 7 22).
—
High Pressure Fuel Lines
The high pressure fuel lines must be cleaned. The ends must not be split or compressed; leakage will result. Make sure when installing that the fuel line fits squarely at both ends and that the fittings are not over-tightened (Fig. 7 — 22). NEVER BEND THE FUEL LINES.
Notes: Worldwide Parts Source Email:
[email protected] -7-9197 of 252
Phone: 269 673 2313
2000 RTF Service Manual
7
— 3.4 Glow Plugs
IMPORTANT
The bar that connects the four glow plugs together is energized when the glow plugs are in use. Keep all pipes, clips and other metal objects away from the bar.
5807
Fig. 7-23
Loosening Glow Plug
To check glow plug continuity:
(1 )
Remove the bar from the top of the glow plugs.
(2)
Connect a 1 2V/6W test lamp to the positive ( + ) terminal of the battery.
(3) Check the operation of the test lamp by connecting the other test lead to the cylinder head, to see if the lamp illuminates.
(4) If the test lamp illuminates, connect the test lead to the top of each glow plug, if the test lamp is illuminated the glow plug is good.
B-5808
Fig. 7-24
Removing Glow Plug
(6)
Install a new glow plug and tighten to 1 1 ft. -lbs. (1 5 Nm) torque.
(7)
Install the bar on the top of the glow plugs.
Resle
(5) If the test lamp does not illuminate, remove the glow plug (Fig. 7 — 23 and 7-24).
To check electrical supply to the glow plugs:
( 1 ) Connect a 1 2V/6W test lamp on the top of the glow plug the farthest from the supply connection.
(2)
Connect the other end of the test lamp to the cylinder head.
(3) Turn the ignition switch to the "Pre-heat" position, the test lamp must illuminate.
(4) If the test lamp does not illuminate, check the switch and the electrical connections.
Notes: Worldwide Parts Source Email:
[email protected] 198 of 252
-7-10-
Phone: 269 673 2313
2000 RTF Service Manual
7-4 ENGINE AND ATTACHING PARTS 7
— 4.1 Removing the Engine Lift and block the Bobcat Forklift (See Paragraph 1 — 2, Page 1 — 1 ). Install the frame lock. (1)
(2)
Remove the rear door (See Paragraph 5 — 6.1, Page 5 — 3). B-5821
B-5820
(3)
Remove the batteries from the machine (See Paragraph 6—5, Page 6 — 6).
Fig. 7-25
Engine Harness Connector
(4)
Disconnect the engine wiring harness (Fig. 7 — 25).
(5)
Remove the glow plug wire from the relay (Fig. 7 — 26).
(6)
Disconnect the ground wire at the left side of the engine.
(7)
Remove the air cleaner hose shield and remove the air cleaner hose.
(8) Disconnect the throttle rod at the right side of the engine block (Fig. 7-27).
Fig. 7-26
Solenoid Wires
Fig. 7-27
Injection Pump Linkage
(9) Remove the rear grill (See Paragraph 5 — 2.1, Page 5—1).
the radiator cap.
Resle
(10) Remove
(11) Open the drain plug on the engine block (Fig. 7 28).
—
NOTE:
Put a hose over the end of the coolant drain to make the coolant removal easier.
B-5823
B-4256
Fig. 7-28
Engine Coolant Drain
Fig. 7-29
Radiator Hose
Fig. 7-31 Hose Assembly
Radiator Hose
(1 2) Close off the fuel line going to the fuel filter.
(13!
Remove the fuel line at the
fuel filter.
(14)
Remove the hose from the
return line of the fuel injectors.
(15) Remove the radiator hoses from the radiator and the engine (Fig. 7-29, 7-30 & 7-31).
ig. 7-30
Notes: Worldwide Parts Source Email:
[email protected] -7-11-
199 of 252
Phone: 269 673 2313
2000 RTF Service Manual
(16) Remove the exhaust pipe at the muffler (Fig. 7 — 32). (17) Remove the exhaust pipe at the exhaust manifold.
(18) Remove the rear engine mount bolts, washers and nuts (Fig. 7-33). (19) Remove the front engine mount bolts, washers and nuts (Fig. 7 — 34) (both sides).
8-5827
Fig. 7-32
Exhaust Pipe
Fig. 7-33
Rear Engine Bolts
(20) Install the engine removal table (Fig. 7 — 35, Item 1).
(21) Lift the rear of the engine over the edge of the machine frame with pry
bars. (22) Slide the engine out of the machine onto the table.
Right Front Engine Mount
7 — 4.2 Installing the Engine (1 ) Move the engine into the machine from the table until the universal joint is in the blower housing.
Have a second person reach behind the blower housing on the hydrostatic pump side and guide the universal joint into the splines of the hydrostatic pump shaft while the engine is moved toward the front of the machine. (3)
After the engine is in the correct position, remove the table.
(4) Install the front and rear engine mount bolts, washers and nuts. Tighten the bolts and nuts to 1 25 - 1 40 ft. -lbs. (169- 190 Nm) torque.
(5)
Install the air intake hose. Attach upper hose shield above the valve cover.
(6)
install the exhaust pipe at the manifold and the muffler.
(7)
Connect all the radiator hoses at the engine and the radiator.
(8)
Connect the fuel line at the water filter and the injector return line.
(9)
Connect the throttle rod at the right side of the engine block.
B-431 6
Fig. 7-34
Front Engine Bolts
f)li:
(10) Connect the ground wire at the engine. (11) Connect
the wire at the solenoid and the wire harness together.
(12) Put 50/50 premixed coolant (ethylene glycol and water) in the radiator and recovery tank and install the radiator cap.
(13) Install the rear grill (See Paragraph 5 — 2.2, Page 5 — 1 ).
Notes: Worldwide Parts Source Email:
[email protected] -7-12200 of 252
Fig. 7-35
Engine Removal
Phone: 269 673 2313 2000 RTF Service Manual
Resle
(2)
(14) Install
the batteries (See Paragraph 6—5, Page 6 6).
—
(15) Install the rear door (See Paragraph 5 — 6.2, Page 5—3). (1 6)
Check the engine oil.
(1 7) Start the engine and check for leaks. Check the coolant recovery tank. Add coolant as needed.
(18) Remove the jackstands from
B-4332
under the frame. Fig. 7
— 36
Shield Bolt
B-4335
Fig. 7-37
Removing Shield
7 — 4.3 Blower Housing Shield Removal (1) Remove the engine Paragraph 7 — 4.1 ).
(See
Remove the bolts at the bottom of the shield (Fig. 7 — 36).
(2)
(3) Remove the shield from the machine (Fig. 7 — 37).
If the blower housing shield is removed without removing Fig. 7-38 the engine, remove the exhaust pipe, radiator hose and air intake hose.
NOTE:
B-4337
Engine Coolant Drain
Fig. 7-39
Radiator Hose
Installation Install the shield in the machine above the engine.
(2)
Install the bolts and tighten.
(3)
Install the engine (See Paragraph 7 — 4,2).
Resle
(1)
7 — 4.4 Engine Coolant Radiator
Removal
B-4339
(1 )
Remove the rear grill (See Paragraph 5—2.1 , Page 5— 1 ).
(2)
Remove the radiator cap.
(3)
Open the drain plug on the engine block (Fig. 7 — 38).
NOTE:
Put a hose over the end of the coolant drain to make the coolant removal easier.
(4)
Remove the blower housing shield (See Paragraph 7 — 4.3).
(5)
Remove the oil cooler (See Paragraph 7 — 4.7). Remove the radiator hoses from the radiator (Fig. 7 — 39).
(7)
Remove the bolts at the bottom side of the radiator (Fig. 7 — 40). Lift the radiator up over the muffler shield (Fig. 7 — 41 ).
-7-13-
Notes: Worldwide Parts Source Email:
[email protected] 201 of 252
Radiator Bolts
\x— ____
_
i\
jv,
(6)
(8)
Fig. 7-40
.
.
i|
u
. . j
i
M &
Fig. 7-41
.
—
.
...
1
_.
'
rr
R-4340
Removing the Radiator
Phone: 269 673 2313
2000 RTF Service Manual
Remove the radiator from the machine (Fig. 7 — 42).
(9)
Installation (1)
Install the radiator in the machine and install the bolts and tighten.
(2)
Install the radiator hoses and tighten the clamps.
(3)
Install the oil cooler (See Paragraph 7 — 4.7).
(4)
Install the blower housing shield (See Paragraph 7 — 4.5).
(5) Put the correct amount of coolant in the radiator (See Section 8 for the capacity) and install the radiator cap. i-4343
Fig. 7-42
Install the rear grill (See Paragraph 5 — 2.2, Page 5—1).
(6)
Removing the Radiator
7 — 4.5 Engine Blower Housing
Removal (1)
Remove the engine from the machine (See Paragraph 7 — 4.1).
(2)
Remove the blower shield (See Paragraph 7 — 4.3).
bar and bolts at the top edge of the blower housing (Fig.
(4)
Remove the bolt and nut at the bottom of the blower housing, (Fig. 7 — 44).
(5)
Remove the blower housing from the machine (Fig. 7 — 45).
B-4344
Fig. 7-43
Blower w er Housing Bolts
Installation (1) Install the blower housing in the machine.
Install the bottom bolt and
(2) nut.
(3)
Install foam around the shield.
(4) Install the top bar and bolts and tighten.
(5) Install the blower housing shield (See Paragraph 7 — 4.3).
Install the engine Paragraph 7 — 4.2). (6)
Fig. 7
— 44
Blower Housing Rivet
-7-14-
Notes: Worldwide Parts Source Email:
[email protected] 202 of 252
B-4353
B-4346
(See
Fig. 7-45
Iw er Housing Removing Blower
Phone: 269 673 2313
2000 RTF Service Manual
Resle
(3) Remove the 7-43).
7 — 4.6 Engine Muffler
Removal (1) Remove the rear grill (See Paragraph 5 — 2.1, Page 5—1).
(2) Remove the blower housing shield (See Paragraph 7 — 4.3). (3) Remove the from the muffler.
exhaust
pipe
(4) Remove air hose, water hoses and hose clamp over valve cover. 8-4349
Remove the bolts and remove the heat shield (Fig. 7 — 46). (5)
Fig. 7
— 46
B-4351
Fig. 7-47
Muffler Shield
Removing the Muffler
(6) Remove the bolts at the bottom side of the muffler and remove the muffler from the machine (Fig. 7 — 47).
Installation (1) Install the muffler in the machine. Install the bottom bolts and tighten.
(2) Install the heat shield and bolts and tighten. (3) Install air hose, water hoses and hose clamp over the valve
cover. (4) Install the exhaust pipe and tighten the clamp. (5) Install the blower housing shield (See Paragraph 7 — 4.3).
7 — 4.7 Oil Cooler Removing the Oil Cooler
Remove the engine from the machine (See Paragraph 7 — 4.1).
B-4537
B-4536
(1)
Fig. 7 — 48
Oil Cooler Bolts
Fig. 7-49
Oil Cooler Tubeline
(2) Remove the four (4) bolts from the oil cooler (Fig. 7 — 48). (3) Remove the tubelines from the oil cooler (Fig. 7 — 49). (4) Drop the oil cooler down and pull it towards you to remove it from the machine (Fig. 7 — 50).
Installing the Oil Cooler (1) Put the oil cooler in the machine (Fig. 7 — 50).
(2)
Install the tighten.
bolts. Do not
(3)
Connect the tubelines (Fig. 7 — 49) and tighten. (4) Tighten the oil cooler mounting bolts (Fig. 7 — 48).
Install the engine in the machine (See Paragraph 7 — 4.2).
B-4538
(5)
Fig. 7-50
Oil Cooler
Notes: Worldwide Parts Source Email:
[email protected] 203 of 252
-7-15-
Phone: 269 673 2313
2000 RTF Service Manual
Resle
(6) Install the rear grill (See Paragraph 5 — 2.2, Page 5—1).
7-5 CYLINDER HEAD
7 — 5.1 Removing the Cylinder Head (1)
Clean all the debris from the cylinder head and engine area.
(2)
Remove the coolant from the engine. Open the drain on the engine block.
(3)
Disconnect the radiator hoses. B-5795
Fig. 7-51
Remove air intake hose and shield hose clamp.
(4)
Removing Injector Nozzle
(5) Remove the high pressure and low pressure tubelines from the fuel injectors (Fig. 7 — 51) and the injection pump.
(6)
Remove the fuel injectors and washers from the cylinder head (Fig. 7 — 52).
(7)
Disconnect the breather pipe.
(8)
Remove the valve cover from the engine.
(9)
Remove the two nuts from the end support brackets of the rocker arms.
(11) Remove the
(1 2)
Fig. 7-52
Remove the cylinder head bolts.
A-2846
Removing Injector Nozzle
rocker arm assembly.
Remove the push rods from the cylinder head.
Resle
(10)
*=
NOTE: When removing the cylinder head, do not use a sharp tool between the cylinder head and the engine block. Put the cylinder head on a flat surface such as wood, to prevent damage to the machined surface.
(1 3)
B-1855
Remove the cylinder head and the gasket from the engine block. Fig. 7-53
Valve Numbering
7 — 5.2 Removal of the Valves (1) Mark the valves so they are put in the original position (Fig. 7 — 53) when they are installed again.
(2) Use a valve spring compressor to remove the two valve spring locks by compressing the valve springs (Fig. 7 54). Repeat this for each valve to be removed.
—
B-5798
(3)
Remove the spring cups, springs (2), seal and spring seat. The valves are now free to be removed from the cylinder head.
Notes: Worldwide Parts Source Email:
[email protected] -7-16204 of 252
Fig. 7-54
Remove the Valves
Phone: 269 673 2313
2000 RTF Service Manual
7 — 5.3 Reconditioning the Valves and Valve Seats
Use the correct equipment to grind the valves and valves seats. A valve seat (hand operated) cutting tool is shown being used in figure 7 — 55. The angle of the intake valves (Fig. 7 — 56, Item 1 ) is 45° and 30° for the exhaust valves (Fig. 7 — 56, Item 2). Check the valve head depth in the cylinder head as the specifications show in figure 7 — 56.
Fig. 7-55
Recondition the Seats
This depth can be checked by putting a straight edge across the cylinder head and using a feeler gauge (Fig. 7 — 57).
0.65 in. (16,5 mm)
1 .908/1.948 in. When reconditioning valves and valve seats, remove only a minimum amount of metal.
(48,5/49,5 mm)
T
.002-.004 in. (0,051-0,102 mm)-
.0015-.0035 in.jr (0,038-0,089
0.053 in. ( 1,35 mm)
mmj ÿ
,053 in. ( 1,35 mm)
INLET
EXHAUST
7 — 5.4 Installing Valve Guides
PI-2599
Fig. 7-56
Resle
NOTE:
Valve and Valve Seat Specifications
The tools listed will be needed to do the following procedure:
MEL-1 1 36
-
Valve Guide Tool
0.024 in.—. (0,609 mm)
I
MEL-1 1 37 - Puller Bars
(1) Check the valve guide wear with a dial indicator (Fig. 7 — 58). If the movement of the valve in the guide is in excess of the specifications, replace the guides.
B-321 5
Fig. 7-57
Checking Valve Depth
Notes: Worldwide Parts Source Email:
[email protected] -7-17205 of 252
f
Fig. 7-58
Checking Valve Guide
Phone: 269 673 2313
2000 RTF Service Manual
NOTE:
Make sure to check the valve stem for wear before replacing the guides (Fig, 7 — 59).
Minimum Dia. (Inlet)
0.310 in. (7,87 mm) (Exhaust)
(2) Remove the valve guide with a hydraulic press or the removal tool (hand operated) for the valve guides (Fig. 7 — 59).
0.3095 in. (7,86 mm)
Protrusion Above Cylinder Head (Spring Seat Face) Before you install the new guides, remove any metal (burrs) from the bore in the cylinder head. (3)
Valve to Stem Clearance - .005" (0,13 mm)
(Max.) Inlet
(4) Put oil in the bore and press in the new guide or pull them through with the installation tool (Fig.
7-61). PI- 2 3 7 2
Fig. 7-59
Once the guide is started and is moving into the cylinder head bore DO NOT STOP. Use the correct tool to make sure the guide is at the correct height before you stop moving the guide (Fig. 7 — 59).
Resle
NOTE:
Valve Guide Specifications
B-1863
B-2887
Fig. 7 — 60
Fig. 7-61 Valve Guide installation
Valve Guide Removal
---
7 — 5.5 Checking Valve Springs
1.736 in.
28 lbs. ± 1.5 lbs. (12,7 kg ± 0.65 kg)
(44,09 mm)
|
The inner and outer valve springs are the same for both the intake and the exhaust valves.
(37,84 mm)
|
1
VALVE SPRING OUTER
1 .59 in. (40,38 mm) PI-237 1
Fig. 7-62
Valve Spring Specifications
Notes: Worldwide Parts Source Email:
[email protected] -7-18-
206 of 252
40 lbs. ± 2.0 lbs. <18.1 kg ± 0.91 kg)
1
VALVE SPRING iNNER 1.49 in. Check the spring ends for damage and as the specifications shows in figure 7-62.
1 .81 in.
(45,97 mm)
Phone: 269 673 2313
2000 RTF Service Manual
7 — 5.6 Combustion Chamber Inserts
(1) Remove the inserts. Use a short rod through the injector nozzle bore. Hit the rod with a hammer to remove the insert (Fig.
7-63).
8-3251
B-3284
(2) Position the new insert by putting the expansion washers in the correct position (Fig. 7 — 64).
(3)
Fig. 7-63
Fig. 7-64
Removing the Insert
Installing the Insert
Make sure to check the height of the insert to the cylinder head.
Use a hammer and punch to set the expansion washer in position (Fig. 7 — 65) to hold the insert in the head.
(4)
Clean the cylinder head face and the coolant and lubricating oil passages.
Resle
7 — 5.7 Cylinder Head Inspection
o
B-3330
Fig. 7-65
Installing Expansion Washer
Check for cracks and other damage. Check the cylinder head face for distortion. The maximum permissible distortion is 0.004 in. (0,10 mm) across the head (Fig. 7 — 66, Items A and B) and 0.010 in. (0,25 mm) along the head (Items C, D, E and F). If the distortion is more than the tolerance, replace the cylinder head.
NOTE:
DO NOT grind the cylinder head if it is over the maximum limit. Replace with a new cylinder head.
©
8-6259
Fig. 7-66
Cylinder Head Specifications (Flatnessl
Notes: Worldwide Parts Source Email:
[email protected] -7-19207 of 252
Phone: 269 673 2313
2000 RTF Service Manual
7 — 5.8 Installation of the Valves
Exhaust Valve Make sure that the cylinder head and all the parts are clean. (1)
Spring Seat
Outer Spring
Inner Spring
Spring Cup
(2) Put oil on the valve stems to give protection to the guide and valve seal.
Locks
ÿ
Put each valve in the correct location. (3)
Outer Spring
Intake Valve
Inner Spring
1
Seal
(4) Assemble the valve springs and cups as shown in figure
7-67).
Spring Cup B-3355
Fig. 7-67
Valves and Parts
NOTE: The inlet valve stems are fitted with rubber seals. They fit inside the valve springs.
(5) Use spring a valve compressor as shown in figure 7 68. Compress the valve springs and install the valve stem locks.
Resle
—
(6) After the valve spring compressor is removed, tap the valve stem with a hammer a small amount to seat the valve stem locks.
B-3303
7 — 68
Installing Valves
7 — 5.9 Reconditioning the Rocker Arms
Disassembly
( 1 ) Make sure to mark the rocker arms and brackets so they can be put back in the original location when assembling.
Notes: Worldwide Parts Source Email:
[email protected] 208 of 252
-7-20-
Phone: 269 673 2313
2000 RTF Service Manual
(2) Remove the snap rings (Fig. 7 — 69, Item 1) from each end of the rocker arm shaft (Item 2).
(3)
Remove the rocker arms (Fig. 7 — 69, Item 3), brackets (Item 4) and springs (Item 5). After disassembly of all the
(4)
parts, clean them all.
Checking (1) Inspect the rocker arm bushings and shaft for wear as shown in figure 7 — 70.
(2)
NOTE:
Replace any worn parts.
0-2638
Fig. 7-69
Rocker Arm Assembly
When installing a new bushing in the rocker arm, make sure the oil hole is in alignment with the oil hole in the rocker arm (Fig. 7-71).
0.0006-0.0024 In. (0,01-0,06 mm|
Max. = .003 in. (0,076 mm)
Assembly 0.6234/0.6244 in.
(1) Install all the rocker arms, brackets and springs in the reverse order of disassembly (Fig. 7 — 69).
0.625/0.6258 in.
(15,83/15,86
mm)
j_y
(2) Put oil on all the parts for protection.
PI-2595
Fig, 7-70
Resle
(15,87/15,89 mm)
Rocker Arm Specifications
7 — 5.10 Installing the Cylinder Head (1) Check and replace any bent push rods. See figure 7 — 70 for the specifications.
Align Oil Feed Holes
(2) Install a new cylinder head gasket. Make sure the correct type gasket is used. Install it dry. No gasket cement is needed. (3) Install the new gasket on the engine block and position it over the dowels (Fig. 7 72). The gasket is marked "TOP" and
—
"FRONT".
ig. 7-71 Rocker Arm Bushing
Notes: Worldwide Parts Source Email:
[email protected] -7-21-
209 of 252
B-3207
A-2352
Fig. 7-72 installing Head Gasket
Phone: 269 673 2313
2000 RTF Service Manual
(4) Lower the cylinder head into position on top of the gasket. (5)
Install the push rods.
(6) Install the rocker arm assembly over the two studs on the cylinder head (Fig. 7 — 73).
<0>
(7) Put oil on the bolts and nuts and install them.
(8) Use the sequence as shown in figure 7 — 74 and tighten the bolts to 85 ft. -lbs. (1 1 5 Nm) torque in a three step sequence.
NOTE: The bolts for the cylinder head must be tightened again after 15 to 30 hours of engine operation.
B-330 1
Fig. 7-73
Installing Rocker Arm Assembly
(9) Adjust the valve clearance (See Paragraph 7 — 2.2). (10) Install the injector nozzles. (11) Tighten the nuts on the injector nozzles to the torque as shown in figure 7 — 75.
(12) Tighten the
high and low pressure tubelines to the torque as shown in figure 7 75 in a three step sequence.
All Bolts and Nuts 85 ft. -lbs. (115 Nm) Torque
(13) Install the valve cover gasket
and cover.
A-2646
(14) Connect the breather pipe and dipstick. (1 5) Connect all the
Fig. 7-74
Cylinder Head Tighten Sequence
electrical connections. 17 ft. -lbs.
(1 6) Install the hoses for the coolant system.
(23 Nm)
(1 7) Install hoses for the air system and shield. (1 8) Add premixed coolant (50% anti-freeze and 50% water) to the system. (1 9) After the cooling system has been filled, run the engine until it reaches its normal coolant temperature. Stop the engine and tighten the cylinder head bolts again, as shown above with the coolant outlet temperature higher than 77°C. ( 1 70°F.). If the head bolts move when checked, tighten it to the correct torque. If a bolt does not move before the correct torque is reached, loosen the head bolts by 1/12 to 1/6 of a turn (30° to 60°) and then tighten to the correct torque. After all the head bolts have been tightened, check the first 1 0 positions again to be sure that they are still at the correct torque. During the last check do not loosen the head bolts.
1 5 ft. -lbs 20 Nm)
A-2668
(20) Let the engine get cool and adjust the valve tappet clearances.
Notes: Worldwide Parts Source Email:
[email protected] -7-22-
210 of 252
Fig. 7-75 Torque
Phone: 269 673 2313
Specifications
2000 RTF Service Manual
Resle
0
—
7-6 RECONDITIONING THE ENGINE
Make reference to paragraph 7 — 4.1 for removing the engine from the machine and paragraph 7 — 5.1 for removing the cylinder head from the engine block.
7 — 6.1 Pistons and Connecting Rods A-2344
Fig. 7-76
Removing Rod Cap
Removal
(1) Remove the oil Paragraph 7 — 8.2).
pan
(See
(2) Remove the ridges and carbon deposits at the top of the cylinder bore with a ridge reamer.
(3) Rotate the crankshaft until the connecting rods (a pair) are at the bottom dead center. Then remove the nuts from the connecting rod studs.
-3295
Fig. 7-77
Connecting Rod identification Marks
Remove the cap and bearing (Fig. 7 — 76). Make sure the cap and rod have identification marks (Fig. 7 — 77).
Resle
(4)
o
NOTE:
If the bearing is to be used again, it must be marked to identify to its original location. Put marks on the steel (back) face.
o
o
C3
o« ÿ¥7
1-3317
Fig. 7-78 (5) Using a hammer handle, push the piston and rod out through the top of the block (Fig. 7 — 78). Make sure the pistons have identification marks on them (Fig. 7 — 79).
o O X
(6) After the two pistons are removed, rotate the crankshaft 1 80° to put the other pair of pistons in the bottom dead center position.
Removing Piston
ow
yo\
X O X"
yo\
xo
,ÿyx
o
yov J/ 0
Oo OOo OOo OOo o0
B-3248
(7)
Repeat steps 4 and 5.
Fig. 7-79
Piston Identification Marks
Notes: Worldwide Parts Source Email:
[email protected] 211 of 252
-7-23-
Phone: 269 673 2313
2000 RTF Service Manual
Disassembly .096-.097"
.002-.004"
k-1
(1 ) Remove the piston rings from each piston, using a piston ring tool.
.0006.0016"
.002-.003"
(0,0154-0,0406 n
1.1021-1.1024"
1.1022-1.1027"
(27,99-28,00 mm)
.093.094"
.001-.003'
(27,996-28.01 mm)
Use a snap ring pliers to remove the snap ring holding the piston pin in position. (2)
.095-.096"
.1887-1895"
3.499-3.50"* 188,87-88,90 mm)
(3) Remove the snap ring and push the piston pin out.
* Piston Diameter Measured of 90° of Piston Pin Bore Fig. 7-80
NOTE:
pi
2609
Piston Ring Groove Specifications
If the piston pin does not come out easily, do not drive it out. Warm the piston in clean oil to a temperature of 120° (50°C) and push the pin out.
Inspection
Clean all the parts in clean solvent.
Maximum Ring Gap 0.060" (1,5 mm) (2)
B-3334
Inspect the pistons for scoring and ring groove damage.
Fig. 7-81 Checking Ring Gap
(3) Check the clearance of the new piston rings in their grooves by putting them into the groove and using a feeler gauge between the ring and the groove face. The clearance must not be more than the specifications shown in figure 7 — 80. Replace with a new piston when it exceeds this specification.
I
**014-.022 ' (0.356-0.559 mm) T~j
Check piston pin and bushing as shown in figure 7 — 82.
I
!
a
-L—
!
ÿ/-
'Max. Ring Gap = .060" (1,524 mm) Fig. 7-82
PI-2610
Cylinder Bore Specifications
Notes: Worldwide Parts Source Email:
[email protected] -7-24212 of 252
ÿ
J ir f17 ---1
L.
(4) Check the piston ring gap in the cylinder bore (Fig. 7 — 81). Figure 7 — 82 shows the correct specifications for the ring gap.
(5)
Hr
L. u
i
Phone: 269 673 2313
2000 RTF Service Manual
Resle
(1 )
(6) Replace the bushing by removing the old bushing with a hydraulic press. The bore must be cleaned and any burrs removed. Press in a new bushing. Make sure that the oil holes are in alignment. Use the correct size reamer to fit the new bushing to the piston pin (Fig. 7-83).
(7)
0.0006/0.0016" (0,015/0,04 mm)
Check the connecting rod for
1.1021/1.1024"
correct alignment (Fig. 7 — 84).
(28,47/28,00 mm)
1.1022/1.1027"
1.1029/1.1037"
(27,996/28,01 mm)
(28,013/28,034 mm)
7 — 6.2 Installation of Connecting Rod
Piston to PI-2396R
Fig. 7-83
Piston Pin and Bushing Specifications
(1) Install the piston pin in the piston by putting the piston in warm clean oil at a temperature of 100° to 1 20°F. (40° to 50°C.) until the piston pin can easily be pushed into the bushing.
5 in. (127 mm)
I
(2) Position the piston and the connecting rod so that the marks "F" (front) are both in the same
direction.
±0.01 in.
+ 0.01 in.
( ± 0,254 mm)
( ± 0,254 mm)
(3) Push the piston pin into the piston and the connecting rod.
(4) Install new snap rings in each side of the piston. PI-2375
Fig. 7-84
Resle
V
Connecting Rod Specifications
7 — 6.3 Installation of Rings on the Piston
NOTE:
Use an expanding tool (Fig. 7 — 85) to prevent breaking of the rings.
(1)
Hold the connecting rod (with the piston) in a vise.
(2)
Install the oil ring in the bottom groove.
(3)
Install the 2nd and 1st rings on the piston.
(4)
Put oil on the rings so they can move freely in the piston grooves. B-1 868
(5)
Put the ring gaps in position evenly around the piston.
Notes: Worldwide Parts Source Email:
[email protected] 213 of 252
-7-25-
Fig. 7-85
Installing Piston Rings
Phone: 269 673 2313
2000 RTF Service Manual
—
7 6.4 Installing Piston Assembly in the Engine Block
Before the pistons are installed, see paragraph 7 — 6.5 to check if the cylinder bore needs reconditioning.
=oo ®(fr
5>
°
Rotate the engine crankshaft until the crankpins No. 1 and No. 4 or No. 2 and No. 3 cylinders are at bottom dead center. (1)
B-3208
-3337
Fig. 7
— 86
Piston Installation
Fig. 7-87
Installing Rod Cup
Using a ring clamp tool and carefully compress the rings of the piston. (2)
(3) With the "F" to the front of the engine block (water pump end) put the assembly in the cylinder bore (Fig. 7 — 86).
(4) Put oil on the bearing on the cap. Install the lower bearing cap the connecting rod (Fig. 7 — 87).
60 ft. -lbs.
Tighten the nuts on the connecting rod as shown in figure 7 — 88.
(5)
(81 Nm) I-3325
Threads Lightly Oiled Install the other piston using the same procedure.
(6)
Fig. 7-88
Torque Specifications
Resle
(7) Rotate the crankshaft to put the other set of crankpins at the bottom dead center and install the other set of piston assembly using the same procedure.
7—6.5 Cylinder Liners
Checking
The cylinder liners are of cast alloy iron. They are an interference fit in the engine block and are of the dry type.
Boring of these liners to larger size is not possible and new liners must be installed when the old liners have worn over specifications.
Check the cylinder bore with an inside micrometer. Check the liners in three positions (top, center and bottom). The checks must be made at parallel and right angles to the centerline of the cylinder bore, giving six dimensions for each cylinder bore.
The standard bore of the cylinder liner is 3.501/3.502 in. (88,92/88,95 mm). When the bore dimension is 0.006 in. (0,1 5 mm) over standard dimension the liner must be replaced.
Notes: Worldwide Parts Source Email:
[email protected] 214 of 252
-7-26-
Phone: 269 673 2313
2000 RTF Service Manual
Installation
(1)
Remove all the parts from the
engine.
(2) Use a liner removal tool to pull the liners out through the top of the engine block. B-3249
Fig. 7-90
Checking Liner Height
(3) Clean the bore and remove any burrs.
Fig. 7-89
Removing Liner
(4)
Clean all the grease from the liner and dry it.
(5)
Put lubrication on the outside of the liner.
(6)
Push the liner into the engine block using the installation tool (Fig. 7 — 89).
(8) Check the liner height in four positions for the correct height (Fig. 7-90).
Resle
(7) The liner must be above the engine block and not be pressed fully down when it is in the correct position.
0.026/0.031 in. (0,66/0,79 mm) (Max.)
(9) The dimensions for the liner height are shown in figure 7 — 91 . ÿ3.501-3.502 in.
(88,92-88,95 mm)
(10) Follow the same procedure 0.000/0.004 in.
for the other liners.
the cylinder liner to the standard dimensions. (11) Hone
(0,00/0,10 mm) (Min.)
•Max. Worn I.D. = 3.510" (89,154 mm)
Fig. 7-91
Cylinder Liner Specifications
Notes: Worldwide Parts Source Email:
[email protected] -7-27215 of 252
PI-2373
Phone: 269 673 2313
2000 RTF Service Manual
7 — 6.6 Main Bearings
No. 2
The crankshaft has five main bearings. The end play is controlled by thrust washers on both sides of the center main bearing.
Center Main
n0 4 Rear Main No. 5
Front Main Bearing No. 1
Each main bearing cap has an identification mark in relation to the engine block (Fig. 7 — 92).
The arrow on each cap shows the front of the engine. The position of each cap can not be changed from the original location.
A-2669
Fig. 7-92
Main Bearing Cap Identification
Removal
Remove the oil pan (See Paragraph 7 — 8.2).
(2)
Remove the oil pump (See Paragraph 7 — 8.3).
(3)
Remove the bolts from the main bearing caps.
o
1-1865
Fig. 7-93
Removing Bearing Half
(4) Remove the No. 1 main bearing cap and remove the bearing from the cap half.
(5) Remove the top half of the bearing by pushing it in the opposite side of the bearing half using a piece of wood and rotating the crankshaft (Fig. 7 93).
—
(6) On the center main bearing remove the bearing cap and thrust washers from each side of the
bearing cap (Fig. 7
— 94).
/
Fig. 7-94
Center Bearing and Thrust Washer
Notes: Worldwide Parts Source Email:
[email protected] -7-28-
216 of 252
B-3308
Phone: 269 673 2313
2000 RTF Service Manual
Resle
(1 )
(7) Remove the top half of the bearing and thrust washer by pushing on the opposite of the bearing using a piece of wood and rotating the crankshaft (Fig. 7-95).
Installation (1 )
See Paragraph 7 — 6.9 to check the main bearing journals.
(2) Lubricate the new bearings and install them by putting the end, with no tab, into the block and rotate the crankshaft until the tab is on its seat in the
engine block.
1-3289
(3) Install the other bearing half in the main bearing cap. Lubricate and install on the engine block. (4)
Fig. 7-95
Removing the Thrust Washer
Install the bolts and tighten to position the bearing. Then loosen them.
Install the center main bearing by lubricating the new bearing and washer. Put the end with no tab into the engine block. Rotate the crankshaft until the bearing and thrust washer are on their seat.
(5)
(6) Install the other bearing half and washer in the bearing cap and install on the engine block. (7)
Install the bolts and tighten the bearing to position. Then loosen.
85 ft. -lbs.
Install the rear main bearing using the same procedure and install the rear main bearing seal and bolts.
(8)
(115 Nm) B-3345
Fig. 7-96
Tighten all the bolts on the main bearing caps to the torque as shown in figure 7 — 96. (9)
Torque Specifications
Resle
7 — 6.7 Crankshaft End Play
The crankshaft end play is controlled by the thrust washer fitted on each side of the center main bearing. The end play can be checked by either a feeler gauge (Fig. 7 — 97) or a dial indicator (Fig. 7 — 98).
-3347
Fig. 7 — 97 Crankshaft End Play The maximum end play is 0.016 in. (0,41 mm). The fitting of oversize thrust washers can be used to correct the end play if it is over maximum specification (Fig. 7 99).
—
/
7 — 6.8 Crankshaft
Removal (1 )
Remove the oil pan, oil pump and oil suction pipe (See Paragraph 7 — 8.2). B-329 1
(2)
Remove the crankshaft sheave, timing case cover, timing gears and timing cover (See Paragraph 7 — 7.1).
Notes: Worldwide Parts Source Email:
[email protected] -7-29217 of 252
pjg, 7
— 98
Crankshaft End Play
Phone: 269 673 2313
2000 RTF Service Manual
R2
/f\n %\, T Jim T mTOgf W
....
R2
/ t A
R1
L,
y
R1
V t
J
R1
\-i J
R1
u R1
Finished Dimensions for Undersize Crankshafts
2.7485
A
-
2.7490 in.
(69,81 - 69,82 mm)
2.2485
B
-
2.2491 in.
Radii R1
0.146
-
0.1 57 in. (3,7 - 4,0 mm)
Radii R2
0.126
-
0.142 in. (3,2 - 3,6 mm)
B-6258
Fig. 7-99
Crankshaft Dimensions
(3)
Remove the flywheel and flywheel adapter plate (See Paragraph 7 — 10.1).
(4)
Remove the rear main seal (See Paragraph 7 — 6.9).
(5)
Remove the nuts and connecting rod bearing caps (See Paragraph 7 — 6.1).
(6)
Remove the bolts and main bearing caps (See Paragraph 7 — 6.6).
(7)
Lift out the crankshaft for inspection.
Checking
See figure 7 — 99 for all the dimensions of the crankshaft.
NOTE:
You can grind the crankshaft to 0.010 in. (0,25 mm), 0.020 in. (0,51 mm) and 0.030 in. (0,76 mm) undersize (See Paragraph 8 — 2.11, Page 8—10).
Notes: Worldwide Parts Source Email:
[email protected] 218 of 252
-7-30-
Phone: 269 673 2313
2000 RTF Service Manual
Resle
(57,10 - 57,1 2 mm)
Installation ( 1)
Clean the crankshaft and check that all the oil passages are clean and open.
(2)
Clean the engine block (bearing surfaces), lubricate and install the upper
halves of the bearings. NOTE:
(3)
If you do not install new bearings, always put the old bearings back to their original position.
Put the crankshaft, carefully in position.
! Fig. 7-100 Rear Oil
B-5809
Seal
Lubricate and install the upper half of the thrust washer at the center main bearing (Fig. 7 — 95). (4)
(5)
Clean the main bearing caps. Lubricate and install the lower half of the
bearings. (6)
NOTE: (7)
Fit the main bearings in their location.
Make sure that the lower thrust washer is in the correct location. Install the bolts and tighten to 85 ft. -lbs. (115 Nm) torque (Fig. 7 — 96).
(8) Check the crankshaft so that it rotates freely. Check the crankshaft end play (Fig. 7 — 97 or 7 — 98). See figure 7 — 99 for the correct specifications. (9)
Install the rear seal (See Paragraph 7 — 6.9).
(10) Lubricate the connecting rod bearings. Install them in their location (See Paragraph 7 6.4).
(1 1) Install the oil pump and suction
tubeline (See Paragraph 7 — 8.3). 1-6261
(12) Install the oil pan (See Paragraph 7
—
8.2).
Fig. 7
— 101
Resle
—
Rear End Oil Seal Service Points
(13) Install the timing case, timing gears, timing case cover and crankshaft sheave (See Paragraph 7 — 7.1).
(14) Install the flywheel (See Paragraph 7—10.3).
7 — 6.9 Rear Main Bearing Oil Seal The lip type rear crankshaft oil seal is fitted with its rear face in line with the rear face of the oil seal housing (Fig. 7 — 100). If a new seal is to be fitted to a worn crankshaft (Fig. 7—101), the seal can be pressed farther into the housing to 1/8 in. (3 mm) below the housing rear face or, if this position has been used, to 1/4 in. (6 mm) below the housing rear face (Fig. 7 — 102). Lubricate the seal with clean engine lubricating oil before it is pressed in the housing. Be sure that it is pressed in squarely. Damage can occur with the lip seal and extreme care must be used when the lip seal and housing are fitted. Be sure that the location dowels are correctly fitted.
Notes: Worldwide Parts Source Email:
[email protected] -7 — 31-
219 of 252
B-5810
Fig. 7-102 Oil Seal Housing
Phone: 269 673 2313
2000 RTF Service Manual
7-7 TIMING CASE AND GEARS
7 — 7.1 Timing Case Cover
Removal
(1) Loosen the alternator fastening bolts. Remove the adjusting arm bolt and the belt.
Fig. 7
— 103
Crankshaft Sheave Bolt
(2) Remove the crankshaft sheave bolt and washer (Fig. 7 — 103). Remove the sheave from the crankshaft (Fig. 7 — 104).
(3) Remove the cover bolts and nuts from the cover on the timing case and remove the cover (Fig. 7 — 105). Do not damage the rubber oil seal on the crankshaft sheave key.
Installation
(1 )
(2)
B-581
Clean the timing case cover and timing case back plate. Fig. 7-104
Crankshaft Sleeve
Fig. 7-105
Removing Timing Cover
Install a new gasket on the timing case back plate.
(4)
Resle
(3) Put the front cover in position. Make sure you do not damage the front seal on the crankshaft sheave key.
Install the bolts and nuts finger tight only.
(5) Install the crankshaft sheave to center the front seal on the hub of the sheave.
(6)
Tighten the bolts and nuts on the cover.
V NOTE: The crankshaft sheave must be removed to tighten the bolts behind the sheave.
~_
a >—
—
a
(7)
Install the crankshaft sheave, washer and bolt and tighten the bolt to the torque in figure 7—106.
(8)
Install the alternator and belt and make adjustment to the belt.
Notes: Worldwide Parts Source Email:
[email protected] -7-32220 of 252
=__=r
|
ÿ
(245 Nm) Torque
w
Fig. 7-106
B-3325
Sheave Bolt Torque
Phone: 269 673 2313
2000 RTF Service Manual
7 — 7,2 Front Seal 0.20" (5 mm)
Removal
(1) Remove the timing case cover (See Paragraph 7 — 7.1).
Use a press to remove the oil seal from the timing case cover by pushing out through the front.
B-31 94
B-3230
(2)
Fig. 7-107
Installing Front Seal
Fig. 7-108
Front Seal Dimensions
Installation
(1 )
Put the new seal in position so the rubber seal goes to the inside.
(2) Press the new seal in from the front until the seal is seated below the edge of the front cover (Fig. 7—107). (See figure 7 — 108 for the correct specifications).
I-3205
Fig. 7-109
Install the timing case cover (See Paragraph 7 — 7.1 ).
Resle
(3)
Removing Retainer Plate
7 — 7.3 Idler Gear and Hub
Removal
mw (1 )
Remove the timing case cover (See Paragraph 7 — 7.1 ).
(2)
Remove the nuts from the idler gear plate.
(3)
Remove the retainer plate from the idler gear (Fig. 7—109).
(4)
Remove the idler gear (Fig. 7—1 10).
Remove the idler gear hub (Fig. 7 — 111). The idler gear hub has an interference fit. Use a soft hammer to remove it.
Fig. 7-110
Removing Idler
B-3238
(5)
Notes: Worldwide Parts Source Email:
[email protected] -7-33221 of 252
B-3202
Fig. 7—111
Removing Idler Hub
Phone: 269 673 2313
2000 RTF Service Manual
Inspection
See figure 7 — 112 for all the correct dimensions for the idler gear and the hub.
0.0014/0.0033 in. (0,03/0,08 mm)
Installation
1.7303-1.7313" (43,95-43,975
mm):
(1) Make sure the oil passages are clean in the engine block and the hub.
(2)
Install the hub (Fig. 7-1 13).
(3) Turn the engine crankshaft until the No. 1 piston is at TDC.
1.7327-1.7336"
0.006/0.012 in.
(44,01 1-44,033 mm)
Install the idler gear to the hub. Make sure the timing marks are in alignment with the crankshaft gear, camshaft gear, fuel pump gear and idler gear (Fig. 7-1 13). (4)
(0,1 5/0,30 mm)
(5) Install the retainer plate on the studs (Fig. 7 — 109).
PI-2593
Fig. 7-112
Idler Gear Specifications
Tighten the nuts to the torque as shown in figure 7—1 14. (6)
50 ft. -lbs. (68 Nm) torque
Check the clearance for the end play of the idler gear (Fig. 7-115). See figure 7-112 for (7)
50 ft. -lbs. (68 Nm) torque
Resle
the correct specifications. (8) Check the clearance at the teeth of the gears (Fig. 7—116). See figure 7—117 for the correct specifications.
23 ft. -lbs. (28 Nm) torque
Replace any worn part that does not meet the specifications limits. (9)
Fig. 7-113
Timing Mark Location
Fig. 7-115
Checking End Play
Fig. 7-114
Torque Specifications
Fig. 7-116
Checking Clearance
(10) Install the timing case cover (See Paragraph 7 — 7.1).
7
— 7.4 Camshaft Gear
The tools listed will be needed to do the following procedure:
MEL-1 054 - Puller
Notes: Worldwide Parts Source Email:
[email protected] 222 of 252
-7 — 34-
Phone: 269 673 2313
2000 RTF Service Manual
Removal ( 1)
Remove the timing case cover (See Paragraph 7 — 7.1).
(2)
Remove the bolt, tab washer and retainer washer.
(3)
Install the puller
(4)
Remove the camshaft gear (Fig. 7 — 1 19).
to remove
the camshaft gear (Fig. 7—1 18).
Installation (1 )
Remove the idler gear (See Paragraph 7 — 7.3).
(2)
Put the gear over the end of the camshaft.
(3) Install the retainer washer and the tab washer. (4) Install the bolt and tighten to the correct torque specifications (Fig. 7-114).
Max. Backlash = 0.012" (0,30 mm)
Install the idler gear. Make sure the timing marks are in alignment (Fig. 7— 113). (5)
0.004-0.007" (0,10-0,17 mm
(6)
Check the clearance between the gear teeth (Fig. 7—117).
B-31
(7) Install the timing case cover (See Paragraph 7 — 7.1).
Fig. 7-117
Gear Clearance Specifications
7 — 7.5 Fuel Injection Pump Gear
MEL-1 0475
Resle
The tools listed will be needed to do the following procedure:
- Puller
Removal (1 )
Remove the timing case cover (See Paragraph 7 — 7.1).
(2)
Remove the idler gear (See Paragraph 7 — 7.3).
(3)
Remove the bolt and washer from the gear.
(4)
Install the puller and remove the gear from the injection pump.
ÿm B-3200
Fig. 7-118
Using Gear Puller
Installation (1 ) Install the gear on the injection pump shaft. Make sure the timing marks are in correct alignment (Fig. 7 — 113). (2)
Install the washer and bolt. Tighten the bolt to 51 ft. -lbs. (69 Nm) torque.
(3) Install the idler gear (See Paragraph 7 — 7.3). Make sure the timing marks are in correct alignment (Fig. 7 — 1 13). (4)
Check the clearance between the teeth (Fig. 7 — 117).
(5)
Install the timing case cover (See Paragraph 7 — 7.1).
Notes: Worldwide Parts Source Email:
[email protected] -7-35-
223 of 252
B-3199
Fig. 7-119
Removing Gear
Phone: 269 673 2313
2000 RTF Service Manual
7 — 7.6 Crankshaft Gear The crankshaft gear is an interference fit on the end of the crankshaft. A key is installed between the gear and the crankshaft.
Use a puller to remove the gear.
7 — 7.7 Timing Case
Removal
( 1)
Remove the timing case cover (See Paragraph 7 — 7.1)
(2)
Remove the idler gear (See Paragraph 7 — 7.3).
(3)
Remove the camshaft gear (See Paragraph 7 — 7.4).
(4)
Remove the fuel injection pump gear (See Paragraph 7 — 3.1)
(5)
Remove the fuel injection pump (See Paragraph 7 — 3.1).
o
R\
o/W\0
V (cP
C-2475R
(6)
Remove the bolts and washers from the timing case.
(7)
Remove the two bolts from the oil pan that fasten it to the timing case.
(8)
Remove the timing case (Fig. 7—1 20).
Fig. 7-120
Timing Case
Installation
(1 )
Install the timing case on the engine block (Fig. 7—1 20).
Check that the bottom of the timing case is even with the face of the oil pan attaching surface (Fig. 7 121). (2)
—
(3)
Install and tighten the timing case bolts.
(4)
Install the two oil pan bolts and tighten. B-3254R
(5)
Install the fuel injection pump (See Paragraph 7 — 3.1),
Notes: Worldwide Parts Source Email:
[email protected] 224 of 252
-7-36-
Fig. 7-121 Installing Timing Case
Phone: 269 673 2313
2000 RTF Service Manual
Resle
NOTE: The crankshaft gear does not have to be removed.
(6) Install the gear on the fuel injection pump (See Paragraph 7-7.5).
(7) Install the camshaft gear (See Paragraph 7 7.4).
—
(8) Install the idler gear Paragraph 7 — 7.3).
(See B-3201
(9)
Install the cover on the timing case (See Paragraph 7 — 7.1).
Fig. 7
— 122
Thrust Plate
7 — 7.8 Camshaft and Tappets
Removal
-3307
(1) Remove the timing case cover (See Paragraph 7 — 7.1).
Fig. 7-123
Removing the Camshaft
(3)
Resle
(2) Remove the idler gear (See Paragraph 7 — 7.3).
Remove the rocker arm assembly and the push rods. 1
(4) Turn the engine over and remove the oil pan (See Paragraph
7-8.2).
B-3294
Fig. 7-124
Removing Tappets
(5)
Remove the oil pump (See Paragraph 7 — 8.3).
(6)
Remove the thrust plate at the camshaft (Fig. 7—1 22).
(7)
Remove the camshaft from the engine block (Fig. 7 — 1 23).
(8)
Remove the tappets from the engine (Fig. 7 — 1 24).
NOTE:
Do not damage the camshaft bearings when removing the camshaft.
Notes: Worldwide Parts Source Email:
[email protected] -7-37-
225 of 252
Phone: 269 673 2313
2000 RTF Service Manual
.002.005" (0,051-0,127 mm) Max. .006" (0,152 mm)
Inspection
Check the camshaft and bearings for wear. See figure 7—125 for the correct specifications.
Installation
2.044-2.045 in.
2.0334-2.035 in. (51,66-51,69 mm)
(51,92-51,94 mm) (1)
Lubricate
and
install
0.0012-0.0071 in. 1 (0,030-0,18 mm)
the
tappets.
(2) Lubricate and install the camshaft. Be careful not to damage the cam bearings.
2.024-2.025 in. (51,41-51,44 mm)
Install the camshaft thrust plate and tighten the bolts. (3)
2.0142/2.0154 in. (51,15/51,19 mm)
Install the oil Paragraph 7 — 8.3).
(4)
pump
(See
pan
(See
*Max. End Play = .012" (0,305 mm)
Install the oil Paragraph 7 — 8.2).
(5)
* *Min. 1.673" (42,494 mm) Fig. 7-125
Pl-2397
Camshaft Specifications
(6) Install the camshaft gear (See Paragraph 7 — 7.4).
(See
SPLASH AND OIL MIST TO VALVE AND GUIDE ASSEMBLIES
Resle
(7) Install the idler gear Paragraph 7 — 7.3).
ROCKER
r
Rf?
TT
I
No 2
TT
No 3 BEARING J—
No 1 No 2 BEARING -J-L. BEARING -J-U-
Install the cover on the timing case (See Paragraph 7 — 7.1). (8)
No 4 uBEARING
!
jptSTONj
(9) Install the push rods and the rocker arm assembly (See Paragraph 7 — 2.1 for the valve clearance adjustment).
TIMING GEARS SPLASH &
SPLASH &
OIL MIST
OIL MIST
No 1 BIG END
CRANK SHAFT
FRONT
No 2 BIG END
No 1
No 2
MAIN BEARING
MAIN BEARING
SPLASH & OIL MIST No 3 BIG
END No 3 MAIN BEARING
OIL
SPLASH &
PRESSURE
OIL MIST
GAUGE
No 4
BIG END No 4 MAIN BEARING
No 5 MAIN BEARING
FUEL PUMP
DRIVE
OIL
COOLER LUB OIL
7-8 LUBRICATION SYSTEM
PUMP
RELIEF VALVE
FILTER
LUBRICATING OIL
SUMP
7 — 8.1 Description of the Lubrication
STRAINER
System PI-2369R
The oil lubrication system is shown in figure 7 — 126.
Fig. 7-126
lubrication System
Notes: Worldwide Parts Source Email:
[email protected] -7-38226 of 252
Phone: 269 673 2313
2000 RTF Service Manual
The lubrication of the engine is done by a full flow filter to the main oil gallery from which the oil is put through small holes into the main bearings housing to each of the five main bearings.
Some of the oil is taken off at a hole at the No. 1 main bearing to lubricate the idler gear and timing gears. Holes in the crankshaft distribute oil to the four connecting rod bearing journals from which oil splash is thrown up to lubricate the cylinder bores and the small ends of the connecting rods.
The four camshaft journals are lubricated directly by oil holes from No. 1 , 2, 4 & 5 crankshaft main bearings. The oil pressure is reduced at the No. 1 journal of the crankshaft and is used to lubricate the rocker shaft. The oil pump has a pressure relief valve which limits the oil pressure. The oil filter housing has a by-pass valve which prevents the engine from going without lubrication if the filter element becomes plugged.
7-8.2 Oil Pan
(1 )
Remove the oil drain plug and drain the oil.
(2)
Remove the fastening bolts from the oil pan.
(3)
Remove the oil pan from the engine block.
Resle
Removal
Installation
Clean the surface of the oil pan where the gasket is installed and the engine block surface. (1 )
(2) Put gasket cement on the oil pan and position the gasket on the oil pan so the holes are in alignment.
(3)
Put the oil pan in position on the engine block.
(4) Make sure that the rear surface of the oil pan and the engine block are straight (use a straight edge).
(5)
Install the bolts and tighten to 1 2-1 5 ft. -lbs. (1 6-20 Nm) torque.
Notes: Worldwide Parts Source Email:
[email protected] -7-39-
227 of 252
Phone: 269 673 2313
2000 RTF Service Manual
7 — 8.3 Oil Pump
Removal
(1) Remove the oil Paragraph 7 — 8.2)
pan
(See
B-58 1 4
B-58 1 2
Fig. 7—127
Oil Tube Bolts
Fig. 7-128
Oil Pump Bolts
(2) Remove the bolts that fasten the oil tube to the engine block (Fig. 7-127).
(3)
Loosen the lock nut on the bolt that holds the oil pump in the engine block and remove the bolt (Fig. 7-128).
(4)
Remove the oil pump from the
4105
Fig. 7-129
Oil Pump Delivery Tube Assembly
Disassembly
(1) Remove the bolts (Fig. 7 — 129, Item 1) and remove the tube (Item 2) from the oil pump.
(2) Remove the bolts (Fig. 7 — 129, Item 3) and remove the tube (Item 4) with the screen.
(3) Remove the relief valve plunger and spring from the oil pump housing (Fig. 7—130).
B-58 1 5
Fig. 7
— 130
Oil Pump Relief Valve
Notes: Worldwide Parts Source Email:
[email protected] 228 of 252
-7-40-
Phone: 269 673 2313
2000 RTF Service Manual
Resle
engine block.
Remove the bolts (Fig. 7—131, Item 1) and remove the end cover (Item 2) from the housing. (4)
(5) Remove the outer rotor (Fig. 7—131, Item 3) from the housing.
C-2639
Fig. 7-131 Oil
Pump Assembly
(6) Use a puller and remove the gear (Fig. 7—131, Item 4) from the end of the shaft.
Remove the shaft and the inner rotor (Fig. 7 — 131, Item 5) from the oil pump housing.
Resle
(7)
B-4109
Fig. 7-132
Checking Clearance
Checking
(1 ) Check the clearance between the outer rotor and the housing (Fig. 7 — 132) and between the inner rotor and the outer rotor (Fig. 7—133). See figure 7—134 for the correct specifications.
B-41 10
Fig. 7-133
Checking Clearance
Notes: Worldwide Parts Source Email:
[email protected] -7-41-
229 of 252
Phone: 269 673 2313
2000 RTF Service Manual
Check the end play of the pump (Fig. 7—135). See figure for the correct 7—134 specifications. (2)
.004 in. (0,10 mm)
.006 in.
(3)
If any of the clearance are over specifications, the oil pump must be replaced as an assembly.
(0,1 52 mm)
3
0.625/0,626 in. 15,87/15,90 mm)
Assembly
(1) Install the inner rotor and shaft (Fig. 7—131, Item 5) into the housing.
0.002/0.006 in. (0,05/0,1 5 mm)
(2) Support the inner rotor and shaft and press the gear (Fig. 7—131, Item 4) on the shaft.
i
.006-.008 in. (0,152-0,203 mm)
Install the outer rotor (Fig. 7—131, Item 3). Make sure the chamfered edge goes in the pump housing first (Fig. 7—130).
PI-2592
(3)
(5)
Oil Pump Specifications
relief valve plunger into the pump housing (Fig.
Resle
(4) Install the spring and 7-136).
Fig. 7-134
Install the end cover and bolts, tighten the bolts.
B-31 91
Installation Fig. 7 — 135 (1 )
Checking End Play
Install the oil tube on the oil pump.
" (2)
Install the oil pump into the engine block.
(3)
Install the bolt and the locknut and tighten.
(4)
Install the bolts that hold the oil tube to the engine block and tighten.
ÿ L,
ye(
1 i,
Ti!
-y- B-3192
\\
(5)
Install the oil pan (See Paragraph 7 — 8.2)
Fig. 7-136
Notes: Worldwide Parts Source Email:
[email protected] 230 of 252
-7-42-
Installing the Rotor
Phone: 269 673 2313
2000 RTF Service Manual
7 — 8.4 Oil Filter and Adapter Housing Removal (1 ) Use a filter wrench to remove the oil filter (Fig. 7 — 1 37, Item 1 ).
(2)
Remove the hoses from the filter adapter housing (Fig. 7-137, Item 2).
&JM
(3) Remove the bolt and the adapter housing (Fig. 7—138).
Installation ( 1 ) Clean the surface of the filter adapter housing.
Install the adapter housing and tighten the bolt. Make sure to replace the o-ring and that it is seated correctly. (2)
Fig. 7-137
Oil Filter Location
Put grease on the seal of the new filter element.
(3)
(4) Install the filter element and hand tighten only. (5) Connect the tighten the clamps.
hoses
and
Fig, 7-139
7-9 COOLING SYSTEM
Water Pump
7 — 9.1 Alternator and Water Pump Belt
If the adjustment is too loose, the engine can get too hot and engine failure will result. (See Paragraph 6 — 9.2, Page 6 — 8 for the correct adjustment).
Resle
The wrong adjustment of belt tension will result in wear and failure of the belt and can cause bearing damage, if the adjustment is too tight.
Fig. 7-138
Oil Filter Base
7 — 9.2 Water Pump
Removal (1) Remove the coolant from the cooling system. (2)
Remove the belt shield.
(3) Loosen the alternator adjusting bolt and remove the belt. (4) Remove the four bolts from the sheave and remove the sheave from the water pump. (5)
Remove the hose from the
water pump.
(6) Remove the bolts which hold the water pump to the engine block. Remove the water pump (Fig. 7-139).
B-3206
Fig. 7—140
Water Pump Assembly
Notes: Worldwide Parts Source Email:
[email protected] _7_43.
231 of 252
Phone: 269 673 2313
2000 RTF Service Manual
Installation (Fig. 7 — 140)
Clean the engine block and the water pump housing where the gasket is
(1)
installed. (2)
Put gasket cement on the engine block surface and install the new gasket.
(3)
Install the water pump on the engine and tighten the bolts.
(4)
Install the hoses.
(5)
Install the sheave and install the four bolts and tighten them.
Install the belt and make the correct adjustment (See Paragraph 6-8.2, Page 6 — 8). (6)
(7)
Install the belt shield.
(8)
Add coolant (50/50 premixed ethylene glycol and
water) to
Fig. 7-141
Thermostat
the system.
7—9.3 Thermostat
Removal (1 )
Remove the coolant from the cooling system.
(2)
Remove the hose from the housing of the thermostat.
Resle
(3) Remove the bolts, housing and thermostat from the engine block (Fig. 7-141).
Testing the Thermostat ( 1)
Put the thermostat in water and heat the water.
.
(2) The thermostat valve must start to open at 179-183°F. (81-8 5°C ) and must be fully open to 0.31 5" (8 mm) at 1 85-200°F. (88-94°C.). (3)
If the thermostat does not open in this range, replace the thermostat.
Installation (1)
Clean the surface of the engine block and housing.
(2)
Put gasket cement on the engine block and install the new gasket.
(3) Install the thermostat and the housing on the engine block and tighten the bolts. (4)
Install the hoses and tighten the clamps.
(5)
Add coolant (50/50 premixed ethylene glycol and water) to the cooling
system.
Notes: Worldwide Parts Source Email: [email protected] 232 of 252
-7 — 44-
Phone: 269 673 2313
2000 RTF Service Manual
7-10 FLYWHEEL 7 — 10.1 Removal of the Flywheel (
1)
(2)
Remove the engine from the machine (See Paragraph 7 — 4.1). Remove the bolts from the u-joint and remove the u-joint from the
flywheel. (3)
Remove only two bolts from the flywheel and install two studs.
(4)
Remove all the bolts from the flywheel.
Remove the flywheel carefully from the crankshaft flange over the studs and from the engine.
(5)
7 — 10.2 Replace the Flywheel Ring Gear (1) The ring gear on the flywheel is an interference fit. Heat the ring gear enough to expand it and hit it with a hammer, evenly, to remove it from the flywheel. (2) The outer surface of the flywheel must be cleaned to give a smooth fit when the new gear is installed.
(3) Clean the new ring gear and heat it to a temperature of -260°C.). The flywheel should be at ambient temperature.
450 - 500°F. (232
(4) Fit the ring gear over the flywheel. Make sure the teeth (angle side) are toward the engine side of the flywheel. Make sure the gear is on its seat correctly.
Resle
7 — 10.3 Installation of the Flywheel (1) Clean the crankshaft flange from all burrs and the area to the flywheel which goes over the flange. (2)
NOTE:
Put two studs in the crankshaft holes.
The flywheel can only be installed in one position because of the hole spacing.
(3) Align the flywheel with the holes in the crankshaft and slide it over the studs. (4) Install the flywheel bolts and tighten to 75 torque (Fig. 7—142). Remove the studs. (5)
- 80 ft. -lbs.
(102 - 108 Nm)
Install the adapter plate and bolts and tighten to 25-28 ft. -lbs. (34-38 Nm)
torque.
(6)
Install the engine in the machine (See Paragraph 7 — 4.2). 8-3327
Notes: Worldwide Parts Source Email: [email protected] -7-45233 of 252
Fig. 7-142
Torque Specifications
Phone: 269 673 2313
2000 RTF Service Manual
Resle 234 of 252
TECHNICAL DATA
DECIMAL AND MILLIMETER EQUIVALENTS ENGINE SPECIFICATIONS Cooling System & Water Pump Dimensions . Crankshaft & Main Bearing Dimensions . . . . Cylinder Block & Liner Dimensions Cylinder Head Dimensions De-Rating for Altitude Engine Torque . Fuel System Specifications Grinding Specifications for Crankshaft .... Oil Pump Dimensions Pistons & Connecting Rod Dimensions .... Timing Case, Camshaft & Drive Dimensions . FORKLIFT SPECIFICATIONS Capacities Drive System Electrical Engine Hydraulics Specifications Tires Vertical Mast HYDRAULIC SYSTEM HYDROSTATIC SYSTEM STANDARD TORQUE SPECIFICATIONS FOR BOLTS U.S. TO METRIC CONVERSION
8-5 8-2 8-2.7 8-2.4 8-2.3 8-2.1 8-2.9 8-2.10 8-2.8 8-2.1 1 8- 2.6 8- -2.2 8- •2.5 8- -1 8- ÿ1.7 8- -1.6 8- -1.5 8- 1 .3 8- 1 .4 8- 1.1 8- 1 .8 8-1.2 8-3 8-4
8-9 8-3 8-5 8-4 8-4 8-3 8-6 8-6 8-6 8-7 8-5 8-3 8-5 8-1 8-2 8-2 8-2 8-1 8-2 8-1 8-2 8-1 8-8 8-8
8-7 8-6
8-10 8-9
Notes: Worldwide Parts Source Email: [email protected]
AWARNING
235 of 252
TECHNICAL DATA
Phone: 269 673 2313
DO NOT service the Bobcat Forklift without instructions or taking the necessary safety precautions. Before working on the machine, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the machine. Failure to obey warnings may cause injury or death.
2000 RTF Service Manual
Resle
Paragraph Page Number Number
Resle 236 of 252
8-1 FORKLIFT SPECIFICATIONS
1 76.0 (4470,4)
(3073,4) (330,2 (2986,0)
92.0 (2336,8)
94.0
50.2
(2387,6)
52.0 1 320,8)
20'
210,8)
58 (1 473,2)
125.0 (31 75,0)
20 (508) 1 67 (4241 ,8)
59.3 (1 506)
PI-2606
Dimensions are given for Rough Terrain Forklift (RTF) equipped with standard mast and may vary with other masts. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Where applicable specifications conform to SAE standards. Specifications are subject to change without notice.
................ ............................ ........................
8—1.1 Specifications
Resle
Weights 7570 lbs. (3434 kg) Shipping Weight 3900 lbs. (1 769 kg) Loader Capacity ( 10' Vertical Mast) ( 1 4' Vertical Mast) 3250 lbs. (1 774 kg) Travel Speed 10 MPH (16.1 km/hr) forward Controls Vehicle Turning is controlled by steering wheel. Speed and direction are controlled by a foot pedal. Engine Hand lever throttle and key type starter switch and shut-down. Hydrostatic Main Drive Brakes Mechanical disc, hand operated lever. Hydraulic Lift and tilt functions operated by single lever control.
........ ......................... ............. ..........
8— 1.2 Vertical Mast Type
. Single stage
Forks: Weight Length/Width/Thickness
8—1.3 Engine Make Model Fuel
1 42.5 lbs. (64,7 kg) each 42.0x 5.0x 1.75(1067 x127 x44,5)
Perkins 4.1 54/200 Series Diesel 54 HP (40,3 kW) 2600 RPM 1 1 4 ft. -lbs. ( 1 53 Nm) @ 2000 RPM 4 3.50 (88.9l-4.00 (101 ,6) 1 54 cu. in. (2522 cm3) Liquid Pressure System W/Filter Open System Replaceable dry paper cartridge with safety element
............................
Horsepower Maximum Governed RPM Torque Number of Cylinders
Bore/Stroke
..............
Displacement Cooling System Lubrication Crankcase Ventilation Air Cleaner
Notes: Worldwide Parts Source Email: [email protected] 237 of 252
-8-1-
CLflRKI r— Division
Machine weight (W,'Standard Tires)
12x16.5x15. 6 Ply
EE3I EES
From factory, this truck r
CAPACITY vith uprighl in vertical position
'ÿs
Part 111. ANSI 856.6 1978
Bismarck. N D. USA
Phone: 269 673 2313
2000 RTF Service Manual
.................... .....................
8 — 1.4 Hydraulics
Pump Engine driven, vane type Pump Capacity 21 .5 GPM (81 ,4 L/min) <8> 2700 RPM System Relief Pressure 2450 PSI ( 1 6893 kPa) Hydraulic Fluid Filter Replaceable cartridge 1 0 micron paper element (1), 3 micron paper element (1) and 40 micron metal filter. Doubleacting Hydraulic Cylinders Bore Diameter 2.875(73) Lift Cylinder 2.50(63,5) TiltCylinder 2.50(63,5) Steering Cylinder Rod Diameter 2.375(60,3) Lift Cylinder 1.25(31,8) TiltCylinder 1.25(31,8) Steering Cylinder Stroke 59.66(1515,4) Lift Cylinder (10' Standard Vertical Mast) 8 1 .80 (2077,8) Lift Cylinder (14' Optional Vertical Mast) 10.00(254,0) TiltCylinder 10.00(254,0) Steering Cylinder 3-spool, open center series type Control Valve Fluid Lines SAE standard full flow tubes, hoses and fittings Rate of Lift 80.0 feet/min. With Maximum Load 85.7 feet/min. Unloaded Rate of Drop 76.9 feet/min. With Maximum Load Unloaded 80.0 feet/min.
.............. ............... ..........................
.................
....................... ........
8—1.5 Electrical Alternator Battery . .
37 amps, open with integral regulator Two (2) batteries, in parallel @ 1 2 volt, 370 cold crank amps. @ 0° F. (-1 7,8 C.) 1 06 min. reserve capacity 1 2 volt gear drive
...............
Starter
Resle
8—1.6 Drive System
Hydrostatic, infinitely variable, fully reversing (2) Transmission Final Drive Differential Front and Rear Differential Reduction 5.86:1 Drop Gear Ratio (Rear Differential) 2.125:1 Fluid Type Hydraulic/Hydrostatic System Clark Bobcat Fluid (P/N 6563328) or 1 0W-30/1 0W-40 Class SE motor oil Front and Rear Axles . . . . SAE 90W gear oil (with limited slip additive in rear axle) 8—1.7 Capacities Cooling System
Fuel Engine Lubrication W/Filter Hydraulic/Hydrostatic System Hydraulic/Hydrostatic Reservoir Front Axle Rear Axle
.....................
22 qts. (21 L) 1 8 gal. (68 L) 7.5 qts. (7,1 L) 44 qts. (4 1 ,6 L) 28 qts. (62,5 L) 6 pints (5,7 L) 1 1 pints ( 1 0,4 L)
8—1.8 Tires Standard Pressure Front Rear
1 2 x 1 6.5, 6-ply Rating, Nylon W/Bar Lug
50 PSI (345 kPa) 40 PSI (276 kPa)
Notes: Worldwide Parts Source Email: [email protected] 238 of 252
-8-2-
Phone: 269 673 2313
2000 RTF Service Manual
..
8-2 ENGINE SPECIFICATIONS
AH dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
8 — 2.1 Cylinder Head Dimensions Cylinder Head Grinding Allowance Valve Seat Angle Valve Seat Width
DO NOT GRIND
............. ....... ........... .......................... ..........
Combustion Chamber Inserts Height of Insert to Cylinder Head Surface
Valve Guides, Inlet & Exhaust Guide Height Above Cylinder Head Maximum Clearance Between Valve and Guides
45°, Inlet; 30°, Exhaust
0.079 (2,0 mm)
0.001 (0,02) Above 0.0029 (0,07) Below
0.65 (1 6,5) 0.005 (0, 1 27), Inlet;
0.0055 (0,14 mm), Exhaust
Valves, Inlet
Minimum Worn Valve Stem Diameter Maximum Worn Clearance of Valve Stem in Guide Minimum Valve Head Thickness Valve Face Angle Valve Stem Seal Head Diameter Valves, Exhaust
0.310(7,88) 0.005(0,13) 0.053(1,35)
45° Synthetic Rubber Deflector
Minimum Worn Valve Stem Diameter Maximum Worn Clearance of Valve Stem in Guide Minimum Valve Head Thickness Valve Face Angle Valve Stem Seal Head Diameter
1.591/1.598(40,4/40,6)
0.3095(7,87) 0.0055(0,14) 0.053(1,35)
........................ .............
1 .49 (37,84) 28 lbs. ± 1 .5 lbs. (1 2,7 kg ± 0,65 kg)
............. ......... ...............
Valve Springs, Outer Fitted Length Load at Fitted Length Free Length Minimum Free Length Out-Of-Square Tolerance
Resle
Valve Springs, Inner Fitted Length Load at Fitted Length Free Length Minimum Free Length Out-Of-Square Tolerance
30° Not Used 1.412/1.422(35,87/36,13)
1.736(44,1) 1.654(42,0) 0.049(1,25)
1.58(40,3)
40 lbs. ± 2.0 lbs. (8 1 , 1 kg. ±0,91 kg) 1.81 (54,97)
Rocker Arms Clearance Fit of Rocker Arm Bushing on Shaft Maximum Worn Clearance Inside Diameter of Bushing (Fitted)
1.717(43,6) 0.054(1,37)
...
Rocker Arm Shaft Outside Diameter of Shaft
0.0006/0.0024(0,02/0,06) 0.003(0,08) 0.625/0.6258(15,87/1 5,89)
0.6234/0.6244 (1 5,83/1 5,86)
................ .......... ...........
8 — 2.2 Pistons and Connecting Rod Dimensions
Pistons Type Flat Topped, Controlled Expansion, Offset Piston Pin Piston Diameter (Measured at 90° to Piston Pin and 0.7 (18) Above Bottom of Piston) 3.499/3.500 (88,87/88,90) 1.1022/1.1027(27,996/28,008) Bore Diameter for Piston Pin Ring Groove Width -Top 0.096/0.097 (2,43/2,45) 0.095/0.096(2,42/2,44) 2nd 0.1887/0.1895(4,79/4,81) Bottom
................... ..............
Notes: Worldwide Parts Source Email: [email protected] 239 of 252
-8-3-
Phone: 269 673 2313
2000 RTF Service Manual
8 — 2.2 Piston and Connecting Rod Dimensions (Cont'd) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
.................... .......................... ................... ................... ..............
Pistons Rings Compression (Top) Compression (2nd) Scraper (3rd) Ring Width -Top & 2nd Bottom Ring Clearance in Groove
Chrome Insert Internally Stepped Chrome Faced Coil Spring Loaded, Oil Control 0.093/0.094(2,36/2,33)
.............. .............. ........... .................. ......................... .................... ............................. .............. ........... ...................... .................. ................... .................. ........ ......... ................... ............... ................. .......... .......................
0.1867/0,1874(4,74/4,76) 0.002/0.004(0,05/0,09) 0.002/0.004(0,04/0,08) 001/0.003(0,03/0,07) 0.012(0,30) 0.060(1,5)
— Top
2nd Bottom Maximum Ring Clearance in Groove * Ring Gap (Maximum)
* The ring gap is measured in a clean un-worn part of the cylinder bore.
Piston Pins Type Clearance Fit in Small End Bushing Maximum Worn Clearance Outside Diameter
Fully Floating 0.0006/0.0016(0,01/0,04) 0.002 (0,05) 1.1021/1.1024(27,994/28,000)
Connecting Rods Type Maximum Side Play at Big End Small End Bushing Inside Diameter
"H" Section 0.016 (0,40) Steel Backed, Bronze Lined 1 . 1 029/1 . 1 037 (28,014/28,035)
Connecting Rod Bearings Type Rod Bearing Running Clearance Maximum Clearance
Steel Backed, Aluminum Tin Lined 0.0015/0.003(0,04/0,08) 0.004(0,10)
Cylinder Block Bore Diameter of Cylinder Liner Main Bearing Bore No. 1 Bore for Camshaft No. 2 Bore for Camshaft No. 3 Bore for Camshaft No. 4 Bore for Camshaft Cylinder Block Surface Distortion Limit
Tappet Bore Diameter
—
Resle
8 — 2.3 Cylinder Block and Liner Dimensions
3.8125/3.8135(96,84/96,86) 2.916/2.917 (74,07/74,09) 2.0472/2.048(52,0/52,03) 2.037/2.038(51,75/51,78) 2.028/2.029 (51,5/51,53) 2.018/2.019(51,25/51,28) 0.010(0,25) Longitudinal 0.004(0,10) Transverse 0.563/0.564(14,29/14,32)
Cylinder Liners Type Dry Interference Fit 3.501/3.502(88,93/88,95) Cylinder Liner Finished Bore 3.510(89,15) Maximum Worn Bore Diameter Depth of Flange BELOW Top Face of Cylinder Block . 0.000/0.004 (0,00/0, 1 0) Heightof Collar ABOVE Top Face of Cylinder Block . . 0.026/0.031 (0,66/0,79)
8 — 2.4 Crankshaft and Main Bearings Dimensions
Crankshaft Main Journal Diameter 2.7485/2.7491 (69,81/69,82) 0.002(0,5) Maximum Journal Wear Crankshaft Rod Journal Diameter 2.2485/2.2491 (57,10/57,12) 0.002(0,5) Maximum Rod Journal Wear Main Journal & Rod Journal Diameter Out-of-Round Permitted . . 0.0005(0,01) Crankshaft End Play 0.006/0.01 5 (0, 1 4/0,38) 0.016(0,40) Maximum End Play
Notes: Worldwide Parts Source Email: [email protected] 240 of 252
-8-4-
Phone: 269 673 2313
2000 RTF Service Manual
8 — 2.4 Crankshaft and Main Bearings Dimensions (Cont'd) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
............. ..... ......... .................. .................. ............ ....................... ......... ........................ .......... ........................ ......................... ..............
Main Bearings Type Main Bearing Running Clearance Maximum Clearance
Steel Backed, Aluminum Tin Lined
..
0.0024/0.0035(0,06/0,09) 0.005(0,13)
Crankshaft Thrust Washers Type
Steel Backed Aluminum Tin Center Main Bearing
Position in Cylinder Block Thrust Washer Oversize .
0.007(0,18)
8 — 2.5 Timing Case, Camshaft and Drive Dimensions
Camshaft Journal Diameter, No. 1 Journal Diameter, No. 2 Journal Diameter, No. 3
2.044/2.045(51,91/51,94) 2.034/2.035(51,66/51,69) 2.024/2.025(51,41/51,44) 2.014/2.015(51,16/51,19) 0.002/0.005(0,06/0,12) 0.006(0,15) 0.003(0,08) 1.673(42,49) 0.001/0.007(0,02/0,18) 0.012(0,30)
Journal Diameter, No. 4 Journal Clearance in Cylinder Block Maximum Journal Clearance Maximum Camshaft Runout Minimum Cam Height Camshaft End Play Maximum End Play
Idler Gear and Hub Clearance Fit of Gear Bushing on Hub Idler Gear End Play Maximum End Play Inside Diameter of Gear Bushing
0.0014/0.0034(0,03/0,09) 0.008/0.01 2 (0,20/0,30) 0.015(0,38) 1.7327/1.7336(44,01/44,03)
Timing Gears All Gears Backlash Maximum Backlash
0.004/0.007 (0,10/0,17)
Resle
0.012(0,30)
8 — 2.6 Oil Pump Dimensions Oil Pump Pressure
30-60 PSI (207 - 41 4 kPa)
Oil Pump Clearance of Inner to Outer Rotor maximum Inner to Outer Rotor Clearance of Outer Rotor to Pump Housing Maximum Outer Rotor to Housing Rotor End Play Maximum Rotor End Play Maximum Shaft to Pump Clearance
.......
Oil Pump Relief Valve Type Spring, Free Length
0.002/0.008(0,04/0,20) 0.01 2 (0,30) 0,006/0.008(0,14/0,20) 0.012(0,30)
0.002/0,004(0,04/0,10) 0.006(0,15) 0.004(0,10)
Spring-Loaded Plunger 1.6(40)
8 — 2.7 Cooling System and Water Pump Dimensions Water Pump Type
.....................
Thermostat Type Opening Temperature Fully Open Temperature
Centrifugal
Wax By-Pass Blanking 1 77/1 82°F (80, 5/83, 5°C) 203°F (95°C)
Notes: Worldwide Parts Source Email: [email protected] 241 of 252
-8-5-
Phone: 269 673 2313
2000 RTF Service Manual
.
8 — 2.8 Fuel System Specifications
AH dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
...........................
parentheses.
Fuel Filter Type
Combination fuel filter and water trap
Fuel Injection Pump Manufacturer Type
Rotation
Plunger Diameter Cam Lift Static Timing
Fuel Injectors Type Operating Pressure
Diesel Kiki VE Clockwise (from drive end) 0.394(10)
0.09(2,2)
0.039 ( 1 ) cam lift at TDC
................
Pintle 1 920/1 990 PSI (1 3238/1 3721 kPa)
Starting Aid-Glow Plugs Type Voltage and Current
Sheathed 1 0. 5 volt - 6 . 5 amps.
8 — 2.9 De-Rating for Altitude
The following is given as a general guide, which may be used on a percentage basis, where specific figures for an engine rating are not available.
0 - 2,000 ft. (600 Meters) 2,000 - 4,000 ft. (1 200 Meters)
4,000 - 6,000 ft. (1 800 Meters) 6,000 -8,000 ft. (2400 Meters) 8,000 - 10,000 ft. (3000 Meters) 10,000 - 1 2,000 ft. (3600 Meters)
Maximum Fuel Delivery De-Rating Measured at 800 RPM Pump Speed No Change 6% 12% 18% 24% 30%
Resle
Altitude
Any necessary adjustment for the fuel injection pump must be done by Trained
Service Personnel.
8 — 2.10 Engine Torque
The following figures will apply with the bolts and/or nuts having a light coat of oil before assembly. Bolt and/or Nut
Cylinder Head Bolts (Also Rocker Arm Brackets) Main Bearing Bolts Connecting Rod Nuts* Flywheel Bolts Crankshaft Sheave Retaining Bolt
Camshaft Gear Bolt Idler Gear Hub to Cylinder Block Nuts Fuel Injection Pump Drive Gear Nut Fuel Injector Nuts High Pressure Tubelines Fittings Glow Plugs
..... Ft.-Lbs.
Nm
85 85 60 75-80 180 50 21 50 17 15 11
115 115 82 102-108 245 68 28 69 23 20 15
* Once the Connecting Rod Nuts are removed, they must be replaced.
Notes: Worldwide Parts Source Email: [email protected] 242 of 252
-8 — 6-
Phone: 269 673 2313
2000 RTF Service Manual
8 — 2.1 1 Grinding Specifications for Crankshaft
B-6258
0.010 in. (0,25 mm) Undersize
A
B
0.030 in. (0,76 mm) Undersize
0.020 in. (0,51 mm) Undersize
2.7385-2.7391 in.
2.7285-2.7291 in.
2.7185-2.7191 in.
(69,558-69,571 mm)
(69,304-69,317 mm)
(69,050-69,063 mm)
2.2385-2.2391 in.
2.2285-2.2291 in.
2.2185-2.2191 in.
(56,858-56,871 mm)
(56,604-56,617 mm)
(56,350-56,363 mm)
Radii R1
0.146-0.1 57 in. (3,7-4,0 mm)
Radii R2
0.126-0.142 in. (3,2-3,6 mm)
Notes: Worldwide Parts Source Email: [email protected]
-8-7243 of 252
Phone: 269 673 2313 2000 RTF Service Manual
Resle
Crankshaft Regrind Data
.........................
8-3 HYDRAULIC SYSTEM Type Capacity
Engine driven, Vane type 2 1 .5 GPM (8 1 ,3 L/m) @ 2600 RPM
Priority Valve Flow
...... ...........
Hydraulic Control Valve System Relief Pressure Tilt Section Lift Section
Hydraulic Fluid Filter
Steering Relief Valve Port Block
7.3 GPM (27,6 L/m) to steering, 1 4.2 GPM (53,7 L/m) to hydraulic circuit 3 spool, open center 2450 PSI ( 1 6893 kPa) (shim adjustable) Self center in neutral Self center in neutral
.......
Replaceable cartridge 1 0 micron ( 1 ) & #3 element ( 1 ) and 40 micron bronze (1) 2000 PSI ( 1 3790 kPa) 40 micron bronze filter
......................... ............................ ..........................
8-4 HYDROSTATIC SYSTEM
Pump Two (Tandem) engine driven, piston type Charge Pressure (At 1 50°F [63°C] Fluid Temperature) Neutral 260/280 PSI ( 1 793/1 93 1 kPa) Stroked* 225/235 PSI (1 552/1 620 kPa) Charged Pressure (At 1 20°F [49°C] Fluid Temperature) Neutral 265/285 PSI (1 827/1 965 kPa) Stroked* 230/240 PSI ( 1 586/1 676 kPa) Replenishing Valves 4 valves
............................ ..........................
Servo Control Valve Type Maximum Valve Stroke
Motor
.......
Self Compensating 1 .74" (44 mm) from neutral in either direction
..................... ...................
Type Displacement
Port Block
Filters
Resle
'The hydrostatic pumps must be stroked into full forward position.
Double opposed piston type, fixed cam angles 8.37 cu. in. (137, 2 cm3) per revolution
Tow Valve High Pressure Relief Valves (2) = 4500 PSI (31028 kPa) Spool type shuttle Stroked Charge Relief = 225 PSI (1551 kPa)
............. ........
10 micron with 30 PSI (207 kPa) by-pass and #3 element with 25 PSI (172 kPa) by-pass
Hydraulic/Hydrostatic System Fluid
Clark Bobcat Fluid (P/N 6563328) or 1 0W-30/1 0W-40 Class SE/SF motor oil
-8-8Notes: Worldwide Parts Source Email: [email protected] 244 of 252
Phone: 269 673 2313
2000 RTF Service Manual
8-5 DECIMAL AND MILLIMETER EQUIVALENTS FRACTIONS
DECIMALS
MM
1/64 0.015625- 0.397 0.03125 - 0.794 3/64 0.046875- 1.191 1/16 0.0625 - 1.588 5/64 0.078125- 1 .984 3/32 0.09375 - 2.381 7/64 0.109375- 2.778 1/8 0.1250 - 3.175 9/64 0.140625- 3.572 5/32 0.15625 - 3.969 1 1/64 0.1 71875- 4.366 - 4.762 3/16 0.1875 13/64 0.203125- •5.159 7/32 0.21875 - 5.556 15/64 0.234375- 5.953 1/4 0.2500 - 6.350 1 7/64 0.265625- 6.747 9/32 0.28125 - 7.144 19/64 0.296875- 7.541 5/16 - 7.938 0.3125 21/64 0.328125- 8.334 1 1/32 0.34375 - 8.731 23/64 0.359375- 9.128 3/8 0.3750 - 9.525 25/64 0.390625- 9.922 13/32 0.40625 - 10.319 27/64 0.421875- 10.716 7/16 - 11.112 0.4375 29/64 0.453125- 1 1 .509 15/32 0.46875 - 1 1.906 31/64 0.484375- 12.303 1/2 0.5000 - 1 2.700
FRACTIONS
1/32
17/32
9/16
19/32
5/8 21/32 1 1/16
23/32
3/4 25/32 13/16
27/32
7/8 29/32 15/16 31/32
1
1 mm = 0.03937"
DECIMALS
MM
33/64 0.515625-13.097 0.53125 -13.494 35/64 0.546875-1 3.891 0.5625 -14.288 37/64 0.578125-14.684 0.59375 -15.081 39/64 0.609375-1 5.478 0.6250 -15.875 41/64 0.640625-16.272 0.65625 -16.669 43/64 0.671 875- 1 7.066 0.6875 -17.462 45/64 0.703125-17.859 0.71875 -18.256 47/64 0.734375-18.653 0.7500 -19.050 49/64 0.765625-19.447 0.78125 -19.844 51/64 0.796875-20.241 0.8125 -20.638 53/64 0.828125-21.034 0.84375 -21.431 55/64 0.859375-21 .828 0.8750 -22.225 57/64 0.890625-22.622 0.90625 -23.019 59/64 0.921875-23.416 0.9375 -23.812 61/64 0.9531 25-24.209 0.96875 -24.606 63/64 0.984375-25.003 1.000 -25.400
0.001" = 0.0254 mm
TO CONVERT LINEAR MEASUREMENT
AREA
VOLUME
WEIGHT
PRESSURE WORK LIQUID VOLUME LIQUID FLOW TEMPERATURE
245 of 252
Miles Yards Feet Feet Inches Inches Inches Square Miles Square Feet Square Inches Acre Cubic Yards Cubic Feet Cubic Inches Tons (Short) Pounds Ounces (Avdp.) Pounds/Sq. In. Foot-pounds
Quarts Gallons
Gallons/Minute Fahrenheit
Resle
8-6 U.S. TO METRIC CONVERSION
MULTIPLY BY 1 .609 Kilometers 0.9144 Meters 0.3048 Meters 30.48 Centimeters 0.0254 Meters 2.54 Centimeters Millimeters 25.4 Square Kilometers 2.59 Square Meters 0.0929 Square Centimeters 6.452 Hectare 0.4047 0.7646 Cubic Meters 0.02832 Cubic Meters 16.39 Cubic Centimeters Metric Tons 0.9078 Kilograms 0.4536 28.3495 Grams Kilopascal 6.895 1 .356 Newton-Metre 0.9463 Liters 3.785 Liters 3.785 Liters/Minute 1 . Subtract 32° Celsius 2. Multiply by 5/9 INTO
-8-9-
2000 RTF Service Manual
8-7 STANDARD TORQUE SPECIFICATIONS FOR BOLTS
THREAD SIZE
INCH. LBS. (Nm)
.250 .3125 .375 .4375
.500
.5625
.625 FOOT LBS. (Nm)
.750
.875 1.000 1.125 1.250
1.375
1.500
1.625
1.750 1.875
2.000
SAE GRADE 5
SAE GRADE 8
80-90
110-120
(9-10)
(13-14)
180-200
215-240
(21-23)
(24-27)
25-28
35-40
(34-38)
(48-54)
40-45
60-65
(54-61)
(82 - 88)
65-70
90-100
(88-95)
(125-135)
90-100
125-140
(125-135)
(170-190)
125-140
175-190
(170-190)
(240-260)
220 -245
300-330
(300-330)
(410 -450)
330-360
475-525
(450-490)
(645-710)
475-525
725-800
(645-710)
(985-1085)
650-720
1050-1175
(880-975)
(1425-1600)
900-1000
1475-1625
(1200-1360)
(2000-2200)
1200-1350
2000-2200
(1630-1830)
(2720-2980)
1500-1650
2600-2850
(2040 - 2240)
(3530-3870)
2000 -2800
3450 - 3800
(2720-2980)
(4680 - 5150)
2500 -2750
4300 -4800
(3390-3730)
(5830 -6500)
3150 -3500
5500-6100
(4270-4750)
(7450 -8300)
3800 -4200
6500 -7200
(5150 - 5700)
(8800-9800)
-8-10246 of 252
Resle
The following table shows standard torque specifications for bolts with zinc phosphate coating.
2000 RTF Service Manual
ALPHABETICAL INDEX Page Number
9-1
Resle
ALPHABETICAL INDEX
ALPHABETICAL INDEX
2000 RTF Service Manual 247 of 252
Resle 248 of 252
Subject
Air Cleaner Service Alarm, Back-up
. Subject
Page
Cylinder Head Dimensions Cylinder Head, Inspection Cylinder Head, Installing Cylinder Head, Removing Cylinder Liners
1—4 1—21,6—11 Alternator 6— 5 7 — 43 Alternator and Water Pump Belt Alternator, Assembling and Installing 6— 8 1—9 Alternator Belt Alternator Belt, Adjusting or Replacing 6— 5 Alternator, Cautions to be Taken in Use of the 6— 2 Alternator, Description 6— 5 Alternator, Disassembling 6— 6 6— 6 Alternator Output, Checking Alternator, Removing 6— 6 6— 5 Alternator Wiring, Checking Axle, Front 4—3 Axle, Front and Rear 1 — 17 Axle, Front, Description 4—3 Axle, Installing the Front 4— 3 Axle, Installing the Rear 4— 3 Axle, Rear 4— 2 Axle, Rear, Description 4— 2 Axle, Removing the Front 4— 3 Axle, Removing the Rear 4—2 Axles, Disassembling and Assembling 4— 4 Axle Serial Numbers 1—2
......
Batteries, Charging the Batteries, Checking the Batteries Installation, New Batteries, Replacing Batteries, Using an Extra Blower Housing, Engine Blower Housing Shield Bronze Bushing, Replacing Bronze (40 Micron) Filter, Replacing
Dash Panel Decimal & Millimeter Equivalents Delivery Report De-rating for Altitude
Differential Assembly End Play, Checking Differential Assembly, Installing Differential Assembly, Removing Differential Oil Level Diodes, Checking Diodes, Description Diodes, Replacing Diodes, Wiring Harness Diode Trio, Checking Door Latch, Adjusting Doors Drive Shaft Drive Shaft, Installing Drive Shaft, Removing Drive System, Description Drive System (Specifications) Drop Gear and Pinion Shaft, Removing
6— 2 6— 3
1—13 6— 3 1—12
Electrical (Specifications) Electrical System Electrical System, Description Electrical System, General Servicing Electrical System, Servicing Electrical System, Troubleshooting End Play, Checking Engine and Attaching Parts Engine, Checks and Adjustments Engine Compression, Check Engine Cooling System Engine, Installing Engine Lubrication System Engine Oil and Filter, Replacement Engine, Reconditioning Engine, Removing Engine Serial Number Engine Service
7—14 7 — 13 5A — 4 2— 5
7 — 37 Camshaft and Tappets 7 — 34 Camshaft Gear Capacities 8— 2 5A— 5 Carriage Chains, Installing 5A — 5 Carriage Chains, Removing 5A — 7 Carriage Rollers, Adjusting Centering Mechanism, Adjusting the Springs in the . . .3 — 7 3— 9 Centering Mechanism, Installing 3— 7 Centering Mechanism, Removing Centering Mechanism, Replacing the Springs in the . . .3 — 8 3—10 Charge Pressure and Replenishing Valves 3 — 10 Charge Pressure, Checking 4—11 Clutch Plates, Installing 4— 1 0 Clutch Plates, Removing 2—7 Cold Weather By-pass Valve, Replacing 7—19 Combustion Chamber Inserts Connections, 37° flare 2—3 7 — 43 Cooling System 8— 5 Cooling System and Water Pump Dimensions 1—9 Cooling System, Removing Coolant from the 2 — 20 Counterbalance Valve 7 — 29 Crankshaft 8— 4 Crankshaft and Main Bearings Dimensions 7 — 29 Crankshaft End Play 7 — 36 Crankshaft Gear Crankshaft, Grinding Specifications 8— 7 8—4 Cylinder Block and Liner Dimensions 7—16 Cylinder Head
249 of 252
Engine Service, T roubleshooting Engine (Specifications) Engine Specifications Engine Torque
Fitting, Straight Thread O-Ring Floorpanels Floorpanels, Installing Floorpanels, Removing Flywheel Flywheel, Installation Flywheel, Removal Flywheel Ring Gear, Replace Foot Pedal and Centering Mechanism Foot Pedal Angle, Adjusting Forklift, Assemblying the Bobcat Forklift, Disassemblying the Bobcat
-9
1-
. Page
—
8 3 7 — 19 7 — 21 7—16 7 — 26
6—1 8— 9 1—2 8— 6 4— 1 3 4— 1 8 4— 7
4— 1 6— 4 6 4 6— 4 6— 4 6 8 1—4 5— 3 4—1 . . . 4— 2 4—1 4— 1 8 2 4— 1 1
—
—
.
—
8— 2 1—9 6—1 6— 2 6— 2 6— 3 4—18 7 — 11 7— 3 7— 3 1—9 7 — 12 1—7 1—8 7 — 23 7 — 11
Resle
9 ALPHABETICAL INDEX
1—2
1—4 7— 1 8—1 8— 3 8— 6
2— 3 5—1 5—1 5—1 7 — 45 7 — 45 7 — 45 7 — 45 3— 7 3— 7 5— 6 5— 4
2000 RTF Service Manual
9 ALPHABETICAL INDEX (Cont'd) Page
Frame Lock Front Seal Fuel Filters Fuel Injection Pump Fuel Injection Pump Gear Fuel Injection Pump, Timing Fuel Injector Nozzles Fuel System Fuel System and Timing Fuel System, Removing Air from the Fuel System Service Fuel System Specifications Fuel Tank Fuel Tank, Installing Fuel Tank, Removing
1—1 7 — 33 1—6 7— 4 7 35 7— 6 7— 7 1—5 7—4 1—6 1—5 8— 6 5-3 5— 3 5— 3
Gear Backlash, Checking Glow Plugs
4 — 21 7—10
Page
Hydrostatic Motor Start-Up Hydrostatic Pump Hydrostatic Pump, Assembly Hydrostatic Pump, Inspection Hydrostatic Pump, Installation Hydrostatic Pump, Removing Hydrostatic Pump Start-up Procedure Hydrostatic Pumps, Disassembly Hydrostatic Pumps to the Manifold Block, Installing . Hydrostatic System Operations Description Hydrostatic System (Specifications) Hydrostatic System, Troubleshooting
—
Idler Gear and Hub
3 — 36 3—12 3 — 19 3—17 3 — 24 3 — 12 3 — 26 3—14 . 3—23 3—1 8—8 3— 2 7 — 33
5A — 6 Lift Carriage, Adjusting 5A— 7 Lift Carriage, Installing 5A — 6 Lift Carriage, Removing 2 — 24 Lift Cylinder, inspecting 2 — 24 Lift Cylinder, Installing 2 — 22 Lift Cylinder, Removing 2 — 20 Lift Cylinder Seals, Checking 1— 1 Lifting and Blocking the Bobcat Forklift Lubrication of the Bobcat Rough Terrain Forklift . . . .1—19 7 — 38 Lubrication System (Engine) 7 — 38 Lubrication System (Engine), Description
4— 5 Hubs, Installing 4— 4 Hubs, Removing 2— 8 Hydraulic Control Valve Hydraulic Control Valve, Description 2— 8 Hydraulic Control Valve, Disassembly 2 — 10 Hydraulic Control Valve, Inspection 2—12 Hydraulic Control Valve, Installing 2—13 2—12 Hydraulic Control Valve, Reassembly 2— 9 Hydraulic Control Valve, Removing 2 — 29 Hydraulic Cylinder, Assembly 2 — 26 Hydraulic Cylinder, Disassembly 2 20 Hydraulic Cylinders 2—4 Hydraulic Fluid, Checking and Adding Hydraulic Fluid Filters, Replacing 2—5 Hydraulic Fluid, Replacing 2—4 1—16 Hydraulic/Hydrostatic Filter, Replacement Hydraulic/Hydrostatic Fluid, Checking and Adding . .1—16 1—16 Hydraulic/Hydrostatic Fluid, Removing 1—14 Hydraulic/Hydrostatic Fluid Reservoir Hydraulic/Hydrostatic System 1—14 2 — 13 Hydraulic Main Relief Valve 2 13 Hydraulic Main Relief Valve, Checking Hydraulic Main Relief Valve, Replacing 2 15 Hydraulic Pump 2—15 Hydraulic Pump, Assembling 2 18 2 17 Hydraulic Pump, Disassembly Hydraulic Pump, Inspection 2 18 Hydraulic Pump, Installing 2—19 2 15 Hydraulic Pump Pressure, Checking Hydraulic Pump, Removing 2—16 Hydraulics (Specifications) 8— 2 Hydraulic System Description 2—1 Hydraulic System Flow Chart 2— 1 Hydraulic System Information 2— 3 2— 1 Hydraulic System Operations Hydraulic System Service 2—4 Hydraulic System (Specifications) 8— 8 2— 2 Hydraulic System, Troubleshooting Hydrostatic Motor 3 26 3 31 Hydrostatic Motor, Assembling Hydrostatic Motor Disassembly 3 27 3 30 Hydrostatic Motor, Inspection 3 — 35 Hydrostatic Motor Installation Hydrostatic Motor Removal 3 27
Machine Serial Number Main Bearing Oil Seal, Rear Main Bearings Manifold Block Assembly Manifold Block Disassembly Mounting Frame, Installing Mounting Frame, Removing Muffler, Engine Muffler, Spark Arrestor
—
Neutral By-pass Valve, Replacing Neutral Start Safety Switch Neutral Start Safety Switch, Checking
— —
Oil Cooler Oil Filter and Adapter Housing Oil Pan Oil Pressure Oil Pump Oil Pump Dimensions Oil Reservoir Oil Reservoir, Installing Oil Reservoir, Removing Operator Cab Orifice in Charge T ubeline, Checking Oscillating Link, Removing
— — — —
Pallet Forks Pallet Forks, Adjusting Pallet Forks, Installing Pallet Forks, Removing Parking Brake Parking Brake, Adjusting Parking Brake Assembly, Installing on the Hydrostatic Motor Housing
— — — —
—
-9-2250 of 252
Subject
1—2 7 — 31 7 — 28 3 — 35 3 — 35 5A— 5 5A — 4 7 — 15 1—20 2—6 3 — 9,6 — 4 6—4
7—15 7 — 43 7 — 39 7— 3 7—40 8— 5 2— 7 2— 7 2— 7 1—21,5—1 3 — 10 5— 5
5A— 1 0 5A — 10 5A— 10 5A— 1 0 4 — 22 4 — 22
4 — 24
2000 RTF Service Manual
Resle
Subject
9 ALPHABETICAL INDEX (Cont'd)
Parking Brake Assembly, Removing from the Hydrostatic Motor Parking Brake Cable, Installing Parking Brake Cable, Removing Parking Brake, Description Pinion Bearing Pre-Load, Setting Pinion Shaft Bearings, installing Pinion Shaft, Installing Pinion Shaft Position, Setting Piston Assembly, Installing in the Engine Block Piston to Connecting Rod, Installation Pistons and Connecting Rods Pistons and Connecting Rod Dimensions
Radiator, Engine Coolant Rear Door, installing Rear Door, Removing Rear Grill Rear Grill, Installing Rear Grill, Removing Rectifier, Checking Regulator, Checking Replenishing Valves Ring Gear, Installing Ring Gear, Removing Rings, Installation on the Piston Rocker Arms, Reconditioning Rotor, Checking
Seat and Seat Plate Seat and Seat Plate, Installing Seat and Seat Plate, Removing Separating the Sections Serial Number Locations Service Schedule Servo Control Servo Control, Assembling Servo Control, Disassembly Servo Control, Installing Servo Control, Neutral Adjustment Servo Control, Removing Side Doors, Installing Side Doors, Removing Specifications Specifications, Forklift Standard Torque Specifications for Bolts Starter Starter, Assembling Starter Brushes, Replacing Starter, Checking Starter, Cleaning and Inspecting Starter, Description Starter, Disassembling Starter, Removing Stator, Checking Steering Control Valve Steering Control Valve, Assembling Steering Control Valve, Disassembly Steering Control Valve, Inspection Steering Control Valve, Installing Steering Control Valve, Removing Steering Cylinder, Removing Steering Cylinder, Installing
Subject
Page
4 — 23 4 — 23 4—23 4 — 22 4—16 4 — 14 4—14 4—15 7 — 26
.....
7 — 25 7 — 23 8— 3 7 — 13 5— 3 5— 3 5—1
Thermostat Tilt Cylinder Seals, Checking Tilt Cylinders, Installing Tilt Cylinder, Removing Timing Case Timing Case and Gears Timing Case, Camshaft ana Drive Dimensions Timing Case Cover Tire Maintenance Tire Rotation Tires (Specifications) T ow Valve Tubelines and Hoses
7 — 44 2 — 21 2 — 25 2 — 24 7 — 36 7 — 32 8— 5 7 — 32 1—18 1—18 8— 2 3 — 36 2— 3
Valve and Valve Seats, Reconditioning Valve Clearance Valve Guides, Installing Valve Springs, Checking Valves, Installation Valves, Removing . . . Vertical Mast Vertical Mast, Inspecting Vertical Mast, Installing Vertical Mast, Removing Vertical Mast Serial Number Vertical Mast (Specifications) Vertical Mast, Troubleshooting
5— 2 5— 2 5— 2 5—4 1—2 1—3 3—4 3— 6 3— 5 3— 6 3— 4 3— 5 5—4 5— 4 8— 1 8—1 8—10 6— 8 6—10 6—10 6— 9
Water Pump Wheel Nuts Wiring Diagrams
...... 8— 9
1—17 4—1
...
7 — 17 7— 3 7— 17 7 18 7 — 20 7 — 16 1 — 2 1 , 5A— 1 5A — 3 5A — 2 5A— 1 1—2 8—1 5A— 1
—
7—43 1—18 6— 1
6—10 6— 8 6— 9 6— 9 6— 7 2 — 30 2 — 35 2 — 31
2 — 34 2 — 39 2 — 31 2 — 26 2 — 26 -9-3-
251 of 252
2 22 2—19
U-Joints, Lubricating
7 — 20 6— 7
—
Steering Cylinder Seals, Checking Steering Relief Pressure, Checking
U.S. to Metric Conversion U-Joints
5—1 5—1 6— 8 6— 6 3—11 4— 9 4— 8 7 — 25
Page
2000 RTF Service Manual
Resle
Subject
Resle
Notes: Worldwide Parts Source Email: [email protected] Phone: 269 673 2313
Last Page 252 of 252
