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EQUIPMENT DESCRIPTION AND DATA
Figure 1. M400T Right-Front 3/4 View.
Figure 2. M400W Right-Front 3/4 View.
Figure 3. Rear View.
Figure 4. Engine Compartment.
Figure 5. NATO Slave Receptacle and Horn.
Figure 6. Battery Access Cover.
Figure 8. Multi-Purpose Bucket.
Figure 10. Auger.
Figure 11. Hammer Attachments.
Figure 12. Attachment Container.
EQUIPMENT DATA
EQUIPMENT DATA CONTINUED
EQUIPMENT DATA CONTINUED
EQUIPMENT DATA CONTINUED
THEORY OF OPERATION
Figure 1. Engine and Hydrostatic Drive.
Figure 2. Powertrain of M400T (Top) and M400W (Bottom).
Figure 3. Cooling System.
Figure 4. Air Intake and Exhaust System.
Figure 5. Hydraulic System.
Figure 6. ISO Pattern Pilot Travel Control System.
HEATING, VENTILATION, AND AIR CONDITIONING (HVAC) SYSTEM
Figure 7. HVAC.
CHAPTER 2. TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM INDEX
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING INTRODUCTION
TROUBLESHOOTING PROCEDURES
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE DOES NOT CRANK CONTINUED
ENGINE TROUBLESHOOTING - ENGINE CRANKS BUT WILL NOT START (NO DIAGNOSTIC CODE)
ENGINE TROUBLESHOOTING - ENGINE CRANKS BUT WILL NOT START (NO DIAGNOSTIC CODE) - Continued
ENGINE TROUBLESHOOTING - ENGINE STALLS
ENGINE TROUBLESHOOTING - ENGINE STALLS CONTINUED
ENGINE TROUBLESHOOTING - ENGINE OVERHEATS
ENGINE TROUBLESHOOTING - ENGINE OVERHEATS CONTINUED
ENGINE TROUBLESHOOTING - ENGINE HAS LOW POWER
ENGINE TROUBLESHOOTING - ENGINE HAS LOW POWER CONTINUED
ENGINE TROUBLESHOOTING - ENGINE RUNS ROUGH OR MISFIRES
ENGINE TROUBLESHOOTING - EXCESSIVE BLACK OR DARK GRAY SMOKE
ENGINE TROUBLESHOOTING - EXCESSIVE WHITE OR BLUE-GRAY SMOKE
HYDRAULIC TROUBLESHOOTING - INCORRECT OR NO LOADER FUNCTION
HYDRAULIC TROUBLESHOOTING - INCORRECT OR NO LOADER FUNCTION CONTINUED
HYDRAULIC TROUBLESHOOTING - INCORRECT OR NO LOADER FUNCTION CONTINUED
POWERTRAIN TROUBLESHOOTING - ONE DRIVE MOTOR (RIGHT OR LEFT) WORKS CORRECTLY AND THE OTHER DOES NOT
POWERTRAIN TROUBLESHOOTING - MACHINE DOES NOT HAVE ENOUGH POWER
POWERTRAIN TROUBLESHOOTING - MACHINE DOES NOT HAVE MOVEMENT
POWERTRAIN TROUBLESHOOTING - MACHINE DOES NOT HAVE MOVEMENT CONTINUED
ELECTRICAL TROUBLESHOOTING - EC001 HYDRAULIC CHARGE PRESSURE IS TOO LOW
ELECTRICAL TROUBLESHOOTING - EC001 HYDRAULIC CHARGE PRESSURE IS TOO LOW CONTINUED
ELECTRICAL TROUBLESHOOTING - EC002 ENGINE OIL PRESSURE IS TOO LOW
ELECTRICAL TROUBLESHOOTING - EC003 HYDRAULIC OIL FILTER IS RESTRICTED
ELECTRICAL TROUBLESHOOTING - EC004 ENGINE AIR INTAKE FILTER IS RESTRICTED
ELECTRICAL TROUBLESHOOTING - EC005 HYDRAULIC OIL TEMPERATURE IS TOO HIGH
ELECTRICAL TROUBLESHOOTING - EC006 ENGINE COOLANT TEMPERATURE IS TOO HIGH
ELECTRICAL TROUBLESHOOTING - EC007 SYSTEM OVER-VOLTAGE/UNDER-VOLTAGE
ELECTRICAL TROUBLESHOOTING - EC007 SYSTEM OVER-VOLTAGE/UNDER-VOLTAGE CONTINUED
ELECTRICAL TROUBLESHOOTING - SSL HARD TO START IN COLD WEATHER/ EC008 CIRCUIT-TO-ALTERNATOR EXCITATION, HVAC RELAY, AND OPTION 1 RELAY IS OPEN
ELECTRICAL TROUBLESHOOTING - SSL HARD TO START IN COLD WEATHER/ EC008 CIRCUIT-TO-ALTERNATOR EXCITATION, HVAC RELAY, AND OPTION 1 RELAY IS OPEN CONTINUED
ELECTRICAL TROUBLESHOOTING - ENGINE CRANKS BUT WILL NOT START/ EC009 CIRCUIT TO FUEL SOLENOID AND STARTER INTERLOCK RELAY IS OPEN
ELECTRICAL TROUBLESHOOTING - MACHINE WILL NOT RUN AFTER ATTEMPTING TO USE ATTACHMENTS/EC010 AUXILIARY OVERRIDE ALTERNATE CIRCUIT TO FUEL SOLENOID IS OPEN
ELECTRICAL TROUBLESHOOTING - LIFT AND TILT FUNCTIONS ARE DISABLED/EC011 HYDRAULIC ENABLE (INTERLOCK) CIRCUIT TO LOADER INTERLOCK VALVE IS OPEN
ELECTRICAL TROUBLESHOOTING - LIFT AND TILT FUNCTIONS ARE DISABLED/EC011 HYDRAULIC ENABLE (INTERLOCK) CIRCUIT TO LOADER INTERLOCK VALVE IS OPEN - CONTINUED
ELECTRICAL TROUBLESHOOTING - WINDSHIELD WIPER AND BLOWER MOTOR INOPERABLE/EC012 GRID HEATER CIRCUIT TO ENGINE PREHEAT RELAY IS OPEN
ELECTRICAL TROUBLESHOOTING - MACHINE AND LOADER ARMS WILL NOT MOVE/EC013 PARKING BRAKE CIRCUIT TO BRAKE VALVE IS OPEN
ELECTRICAL TROUBLESHOOTING - INSTRUMENT PANEL (IP) DOES NOT POWER UP WHEN SEAT IS OCCUPIED
ELECTRICAL TROUBLESHOOTING - JOYSTICK PARKING BRAKE BUTTON INOPERATIVE
ELECTRICAL TROUBLESHOOTING - HORN INOPERATIVE
ELECTRICAL TROUBLESHOOTING - DOME LIGHT/POWER OUTLET INOPERATIVE
ELECTRICAL TROUBLESHOOTING - BACKUP ALARM INOPERATIVE
ELECTRICAL TROUBLESHOOTING - BACKUP ALARM INOPERATIVE CONTINUED
ELECTRICAL TROUBLESHOOTING - FUEL GAUGE INOPERATIVE/INACCURATE
ELECTRICAL TROUBLESHOOTING - ENGINE AIR DUCT HEATER INOPERATIVE
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE CONTINUED
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE CONTINUED
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE CONTINUED
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE CONTINUED
ELECTRICAL TROUBLESHOOTING - ONE OR MORE EXTERIOR LIGHT(S) INOPERATIVE CONTINUED
CHASSIS TROUBLESHOOTING - BLOWER MOTOR INOPERATIVE/DOES NOT OPERATE CORRECTLY
CHASSIS TROUBLESHOOTING - BLOWER MOTOR INOPERATIVE/DOES NOT OPERATE CORRECTLY - CONTINUED
CHASSIS TROUBLESHOOTING - BLOWER MOTOR INOPERATIVE/DOES NOT OPERATE CORRECTLY - CONTINUED
CHASSIS TROUBLESHOOTING - BLOWER MOTOR INOPERATIVE/DOES NOT OPERATE CORRECTLY - CONTINUED
CHASSIS TROUBLESHOOTING - WINDSHIELD WASHER/WIPER INOPERATIVE/DOES NOT OPERATE CORRECTLY
CHASSIS TROUBLESHOOTING - WINDSHIELD WASHER/WIPER INOPERATIVE/DOES NOT OPERATE CORRECTLY CONTINUED
CHASSIS TROUBLESHOOTING - WINDSHIELD WASHER/WIPER INOPERATIVE/DOES NOT OPERATE CORRECTLY CONTINUED
CHASSIS TROUBLESHOOTING - INSUFFICIENT/NO HEAT IN CAB
CHASSIS TROUBLESHOOTING - INSUFFICIENT/NO HEAT IN CAB CONTINUED
CHASSIS TROUBLESHOOTING - INSUFFICIENT/NO HEAT IN CAB CONTINUED
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY CONTINUED
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY CONTINUED
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY CONTINUED
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY CONTINUED
CHASSIS TROUBLESHOOTING - A/C IS NOT COOLING CAB PROPERLY CONTINUED
Table 1. A/C Pressure Readings.
OPERATIONAL CHECKOUT
Fuel Supply System Check
Figure 1. Fuel Injection Pump Supply.
Figure 3. Checking For Air In System.
Figure 4. Fuel Pump Supply.
Misfiring Cylinder Test
Engine Oil Pressure Check
Figure 5. Seat Switch.
Figure 7. Anti-Stall Control Cartridge.
Checking Anti-Stall Pressure
Figure 8. Ground Drive Controller.
Figure 9. Charge Pressure Test Port.
Checking Charge Pressure/Flow - Continued
Figure 10. Access Plate.
Figure 11. Brake Valve.
Figure 13. Male Test Quick Disconnect.
Figure 15. Seat Switch.
Checking Circuit Relief Valve Pressure - Continued
Figure 17. Relief Cartridges.
Figure 18. Brake Valve.
Figure 20. Bypassing Pilot Lines.
Figure 21. Seat Switch.
Figure 23. Pilot Servo Control Adjustment Screws.
Figure 24. Bypassing Pilot Lines.
Figure 25. Bypassing Pilot Lines.
Figure 27. Pilot Servo Control Adjustment Screws.
Figure 28. Flowmeter Connections.
Figure 29. Access Cover for Adjustment Screw.
Figure 30. Loader Main Relief Valve.
Figure 32. Flowmeter Connections.
Flowmeter Tests - Continued
Flowmeter Tests - Continued
Figure 33. Pilot Pressure Test Point.
Figure 34. Seat Switch.
Figure 36. Measure Check Sheet.
Deluxe Instrument Panel Seat Belt Input
CHAPTER 3. PMCS MAINTENANCE INSTRUCTIONS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Preventive Maintenance Checks and Services (PMCS) .
Figure 1. Auger.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 2. Final Drive Motor.
Figure 3. Chain Tank Service.
Figure 4. Final Drive Motor.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 5. Final Drive Motor.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 7. Fuel Tank Drain Plug.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 8. Chain Tank Service.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Table 2. M400T and M400W Skid Steer Loader PMCS Mandatory Replacement Parts List.
CHAPTER 4. MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
SERVICING INSTRUCTIONS
ALTERNATOR REPLACEMENT
Figure 2. Alternator Front View.
Figure 3. Engine Oil Cooler Pipe.
Figure 4. Mounting Bracket Assembly.
Figure 5. Alternator.
Figure 6. Mounting Bracket Assembly.
Figure 7. Engine Oil Cooler Pipe.
Figure 8. Alternator Front View.
Figure 9. Alternator Rear View.
A/C COMPRESSOR REPLACEMENT
Figure 1. A/C Lines.
Figure 2. A/C Compressor and Bracket.
Figure 3. A/C Compressor Mounting Bracket.
Figure 4. A/C Compressor and Bracket.
Figure 5. A/C Lines.
COOLANT RECOVERY BOTTLE REPLACEMENT
Figure 2. Coolant Recovery Bottle.
COOLANT RECOVERY BOTTLE REPLACEMENT - Continued
Figure 3. Rear Access Doors.
ENGINE MOUNTS REPLACEMENT
Figure 1. Engine Mounts.
ENGINE MOUNTS REPLACEMENT - Continued
FAN, PULLEY, AND SHROUD REPLACEMENT
FAN, PULLEY, AND SHROUD REPLACEMENT - Continued
Figure 1. Guard, Shroud, and Fan.
Figure 2. Pulley.
FAN, PULLEY, AND SHROUD REPLACEMENT - Continued
FAN, PULLEY, AND SHROUD REPLACEMENT - Continued
Figure 3. Guard, Shroud, and Fan.
INLINE FUEL FILTER REPLACEMENT
Figure 1. Inline Fuel Filter.
INLINE FUEL FILTER REPLACEMENT
Figure 2. Inline Fuel Filter.
FUEL LINES REPLACEMENT
Figure 1. Fuel Lines.
Figure 2. Fuel Lines.
Figure 3. Fuel Lines.
Figure 4. Fuel Lines.
MUFFLER AND PIPES REPLACEMENT
Figure 1. Exhaust Metal Hose and Muffler.
Figure 2. Tail Pipe and Muffler.
Figure 3. Tail Pipe and Muffler.
Figure 4. Exhaust Pipe and Muffler.
RADIATOR HOSES REPLACEMENT
Figure 1. Radiator Hoses (Engine Shown Removed for Clarity).
STARTER REPLACEMENT
Figure 1. Starter.
Figure 2. Solenoid Cable.
Figure 3. Solenoid Cable.
Figure 4. Starter.
ENGINE ASSEMBLY REPLACEMENT
Figure 1. Engine Hose and Electrical Connections.
Figure 2. Engine Oil Check Tube.
Figure 4. Inline Fuel Filter and Hose.
Figure 6. Front Engine Mount.
Figure 7. Front Engine Mounting Bracket.
Figure 8. Rear Engine Mounts.
Figure 9. Engine Stand Bracket.
Figure 10. Engine Stand Bracket.
Figure 11. Rear Engine Mounts.
Figure 12. Engine Mounting Bracket.
Figure 14. Hoses and Throttle Linkage.
Figure 16. Heater Hose.
Figure 17. Engine Hose and Electrical Connections.
ENGINE ASSEMBLY REPLACEMENT - Continued
ENGINE BLOCK PLUG AND NOZZLES REPLACEMENT
Figure 2. Engine Block Plugs.
ENGINE BLOCK PLUG AND NOZZLES REPLACEMENT - Continued
Figure 3. Turbocharger and Lines.
ENGINE OIL DIPSTICK AND OIL FILL NECK REPLACEMENT
Figure 2. Dipstick.
Figure 3. Engine Oil Fill Neck.
ENGINE OIL DIPSTICK AND OIL FILL NECK REPLACEMENT - Continued
Figure 4. Engine Oil Fill Neck.
Figure 5. Dipstick.
Figure 6. Rear Access Doors.
ENGINE OIL DIPSTICK TUBE REPLACEMENT
Figure 2. Dipstick Tube Bracket.
Figure 4. Dipstick Tube and Clamp.
Figure 5. Dipstick Tube and Clamp.
Figure 7. Dipstick Tube Bracket.
Figure 8. Rear Access Doors.
CLUTCH REPLACEMENT
Figure 2. Clutch Pack.
ENGINE OIL SERVICE
Figure 2. Engine Oil Drain.
Figure 3. Access Cover.
ENGINE OIL SERVICE - Continued
Figure 6. Access Cover.
Figure 7. Engine Oil Drain.
Figure 9. Oil Fill and Dipstick.
CRANKSHAFT PULLEY REPLACEMENT
Figure 2. Crankshaft Pulley.
Figure 3. Alignment Pin/Crankshaft Pulley.
Figure 4. Engine Timing Pin.
ENGINE BREATHER REPLACEMENT
Figure 1. Engine Breather.
ENGINE BREATHER REPLACEMENT - Continued
ENGINE AIR DUCT HEATER REPLACEMENT
Figure 1. Engine Air Duct.
ENGINE AIR DUCT HEATER REPLACEMENT - Continued
ENGINE AIR DUCT HEATER REPLACEMENT - Continued
ENGINE OIL COOLER AND PIPING REPLACEMENT
Figure 1. Heater Hose Supply.
Figure 3. Engine Oil Cooler.
Figure 4. Fitting.
Figure 5. Cooler and Housing Assembly.
Figure 6. Turbocharger Oil Return Pipe.
Figure 7. Heater Hose Supply.
ENGINE OIL FILTER BASE REPLACEMENT
Figure 1. Engine Oil Filter Base.
Figure 2. Engine Oil Filter Base.
ENGINE OIL FILTER BASE REPLACEMENT - Continued
Figure 3. Engine Oil Filter Base.
ENGINE OIL FILTER BASE REPLACEMENT - Continued
ENGINE OIL FILTER REPLACEMENT
Figure 2. Engine Oil Filter.
ENGINE OIL FILTER REPLACEMENT - Continued
ENGINE OIL PAN REPLACEMENT
ENGINE OIL PAN REPLACEMENT - Continued
Figure 1. Oil Pan.
ENGINE OIL PAN REPLACEMENT - Continued
Figure 2. Oil Pan.
ENGINE OIL PUMP REPLACEMENT
Figure 1. Oil Pump Tube.
Figure 2. Oil Pump.
Figure 3. Oil Pump.
Figure 4. Oil Pump Piping.
ENGINE OIL PUMP REPLACEMENT - Continued
EXHAUST MANIFOLD REPLACEMENT
Figure 1. Exhaust Manifold.
EXHAUST MANIFOLD REPLACEMENT - Continued
FLYWHEEL REPLACEMENT
Figure 1. Adapter Plate.
Figure 3. Turning Engine.
Figure 5. Clutch Pack.
Figure 6. Flywheel.
FLYWHEEL REPLACEMENT - Continued
Figure 7. Crankshaft Alignment Hole.
Figure 8. Flywheel.
Figure 9. Clutch Pack.
Figure 10. Timing Pin.
Figure 12. Adapter Plate.
FLYWHEEL HOUSING REPLACEMENT
Figure 2. Oil Pan Bolts.
Figure 3. Flywheel Housing.
Figure 4. Flywheel Housing.
FLYWHEEL HOUSING REPLACEMENT - Continued
Figure 5. Flywheel Housing.
Figure 6. Flywheel Housing.
Figure 8. Clamps.
FLYWHEEL HOUSING REPLACEMENT - Continued
ENGINE FRONT COVER AND FRONT MAIN SEAL REPLACEMENT
Figure 1. Fan Pulley.
Figure 2. Front Cover.
ENGINE FRONT COVER AND FRONT MAIN SEAL REPLACEMENT - Continued
Figure 3. Front Cover.
ENGINE FRONT COVER AND FRONT MAIN SEAL REPLACEMENT - Continued
FRONT HOUSING REPLACEMENT
Figure 2. Flywheel at TDC.
Figure 4. Camshaft Gear and Fuel Injection Pump Gear.
Figure 6. Flanged Nuts.
Figure 8. Front Housing Sealant.
Figure 9. Front Housing.
Figure 11. Aligning Crankshaft Gear.
Figure 13. Pinning Fuel Injection Pump Shaft.
Figure 15. Flywheel at TDC.
FUEL FILTER HEAD REPLACEMENT
Figure 1. Fuel Filter Head.
FUEL FILTER HEAD REPLACEMENT - Continued
FUEL FILTER ELEMENT REPLACEMENT
Figure 2. Fuel Filter Element.
FUEL FILTER ELEMENT REPLACEMENT - Continued
Figure 3. Access Cover.
FUEL INJECTION LINES REPLACEMENT
Figure 1. Fuel Tank.
Figure 2. Hose.
Figure 3. Fuel Injection Tube Assembly.
Figure 4. Fuel Return Pipe.
Figure 5. Fuel Return Pipe.
Figure 6. Fuel Injection Tube Assembly.
Figure 7. Hose.
Figure 8. Fuel Tank.
FUEL INJECTOR REPLACEMENT
Figure 1. Fuel Injector.
Figure 2. Fuel Injectors.
FUEL INJECTOR REPLACEMENT - Continued
FUEL INJECTION PUMP REPLACEMENT
Figure 1. Fuel Injection Pump.
Figure 2. Actuator-to-Engine Throttle Linkage (Rear).
Figure 3. Front Cover.
Figure 4. Fuel Injection Pump.
FUEL INJECTION PUMP REPLACEMENT - Continued
Figure 5. Fuel Injection Pump.
Figure 6. Front Cover.
Figure 7. Actuator-to-Engine Throttle Linkage (Rear).
Figure 8. Fuel Injection Pump.
INTAKE MANIFOLD REPLACEMENT
Figure 1. Manifold.
INTAKE MANIFOLD REPLACEMENT - Continued
REAR SEAL REPLACEMENT
Figure 1. Rear Seal.
Figure 2. Rear Main Oil Seal Installer Base.
REAR SEAL REPLACEMENT - Continued
THERMOSTAT AND HOUSING REPLACEMENT
Figure 1. Thermostat and Housing.
THERMOSTAT AND HOUSING REPLACEMENT - Continued
THERMOSTAT AND HOUSING REPLACEMENT - Continued
TURBOCHARGER AND LINES REPLACEMENT
Figure 1. Turbocharger and Lines.
TURBOCHARGER AND LINES REPLACEMENT - Continued
VALVE COVERS REPLACEMENT
Figure 1. Valve Covers.
VALVE COVERS REPLACEMENT - Continued
WATER PUMP REPLACEMENT
Figure 1. Water Pump (Fan Removed for Clarity).
WATER PUMP REPLACEMENT - Continued
COOLANT TEMPERATURE SENDER REPLACEMENT
Figure 1. Coolant Temperature Sender.
COOLANT TEMPERATURE SENDER REPLACEMENT - Continued
SERPENTINE AND COMPRESSOR DRIVE BELTS REPLACEMENT
Figure 1. Serpentine and Compressor Drive Belts.
SERPENTINE BELT INSTALLATION/ADJUSTMENT
SERPENTINE AND COMPRESSOR DRIVE BELTS REPLACEMENT - Continued
CYLINDER HEAD ASSEMBLY REPLACEMENT
Figure 1. Heater Hose Return.
Figure 2. Engine Harness.
Figure 3. Push Rods.
Figure 4. Cylinder Head.
CYLINDER HEAD ASSEMBLY REPLACEMENT - Continued
Figure 5. Cylinder Head.
Figure 6. Cylinder Head Torque Sequence.
Figure 7. Engine Harness.
Figure 8. Heater Hose Return.
CYLINDER HEAD ASSEMBLY REPLACEMENT - Continued
FAN SUPPORT REPLACEMENT
Figure 2. Spacer.
Figure 4. Fan Support.
FAN SUPPORT REPLACEMENT - Continued
Figure 5. Fan Support.
Figure 7. Spacer.
Figure 8. Fan.
ROCKER UNIT MAINTENANCE
Figure 2. Assembled A/C Compressor and Mounting Bracket.
Figure 3. Housing Removal.
Figure 4. Housing Disassembly.
ROCKER UNIT MAINTENANCE - Continued
Figure 5. Housing Assembly.
Figure 6. Housing Installation.
Figure 7. Assembled A/C Compressor and Mounting Bracket.
ROCKER UNIT MAINTENANCE - Continued
VALVE LASH ADJUSTMENT
VALVE LASH ADJUSTMENT - Continued
Figure 1. Adjusting Valve Lash.
FINDING TOP-DEAD-CENTER (TDC)
Figure 2. Engine Turning Tool.
Figure 4. Timing Pin.
Figure 5. Cover Plate.
Figure 7. Adapter Plate.
AIR CLEANER AND HOSES MAINTENANCE
Figure 1. Air Restriction Switch.
Figure 3. Air Cleaner and Hoses Removal.
Figure 4. Air Cleaner and Hoses Disassembly.
Figure 5. Air Cleaner Cover.
Figure 7. Secondary Element.
Figure 8. Secondary Element.
Figure 10. Air Cleaner Cover.
Figure 11. Air Cleaner and Hoses Assembly.
Figure 12. Relief Valve.
AIR CLEANER AND HOSES MAINTENANCE - Continued
RADIATOR AND COOLER MODULE MAINTENANCE
Figure 1. Module.
Figure 2. Hose and Clamp.
Figure 3. Module.
RADIATOR AND COOLER MODULE MAINTENANCE - Continued
Figure 4. Hose and Clamp.
Figure 5. Module.
COOLING SYSTEM SERVICE
Figure 1. Cooling System Maintenance.
Figure 2. Coolant Level.
CHAIN REPLACEMENT
Figure 1. Chain Tank Cover.
Figure 2. Chains.
Figure 3. Chains.
Figure 4. Chain Tank Cover.
CHAIN TANK SERVICE
Figure 1. Drain Plugs.
Figure 2. Fill Plugs.
POWERTRAIN LINES AND FITTINGS REPLACEMENT
POWERTRAIN LINES AND FITTINGS REPLACEMENT - Continued
Figure 1. Powertrain Lines and Fittings.
POWERTRAIN LINES AND FITTINGS REPLACEMENT - Continued
Figure 2. Powertrain Lines and Fittings.
SPROCKET REPLACEMENT
Figure 1. Sprockets.
SPROCKET REPLACEMENT - Continued
RETURN OIL MANIFOLD REPLACEMENT
Figure 1. Access Panel.
Figure 2. Return Oil Manifold.
Figure 3. Return Oil Manifold.
RETURN OIL MANIFOLD REPLACEMENT - Continued
LH HYDRAULIC DRIVE MOTOR REPLACEMENT
Figure 2. Return Oil Manifold.
Figure 3. Hydraulic Drive Motor.
LH HYDRAULIC DRIVE MOTOR REPLACEMENT - Continued
Figure 4. Hydraulic Drive Motor.
LH HYDRAULIC DRIVE MOTOR REPLACEMENT - Continued
RH HYDRAULIC DRIVE MOTOR REPLACEMENT
Figure 2. Return Oil Manifold.
Figure 3. Hydraulic Drive Motor and Sprocket.
Figure 4. Hydraulic Drive Motor.
Figure 5. Return Oil Manifold.
TANDEM PUMP REPLACEMENT
TANDEM PUMP REPLACEMENT - Continued
Figure 1. Tandem Pump.
Figure 2. Tandem Pump.
Figure 3. Tandem Pump.
Figure 4. Fittings.
Figure 5. Coupling Dimension.
Figure 6. Plate and Coupling.
Figure 7. Tandem Pump.
Figure 8. Tandem Pump.
AXLE MAINTENANCE
Figure 1. Rubber Access Plug.
Figure 3. Axle Hub Assembly.
Figure 4. Axle Removal.
Figure 5. Axle and Hub.
Figure 6. Axle and Hub.
Figure 7. Axle Hub Assembly.
Figure 8. Floor Compartment.
Figure 10. Chain Deflection.
AXLE MAINTENANCE - Continued
BRAKE PILOT VALVE MAINTENANCE
Figure 1. Brake Pilot Valve.
Figure 2. Brake Pilot Valve Solenoids.
BRAKE PILOT VALVE MAINTENANCE - Continued
Figure 3. Brake Pilot Valve Solenoids.
Figure 4. Brake Pilot Valve.
HYDRAULIC OIL FILTER HEAD AND PRESSURE SWITCH REPLACEMENT
Figure 1. LH Access Cover.
Figure 2. Hydraulic Oil Filter Head.
HYDRAULIC OIL FILTER HEAD AND PRESSURE SWITCH REPLACEMENT - Continued
Figure 3. Hydraulic Oil Filter Head.
Figure 4. LH Access Cover.
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT
Figure 1. Hydraulic Oil Filter Element.
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT - Continued
TRACK MAINTENANCE
Figure 2. Chain Link Bushing.
Figure 4. Non-Operational Vehicle.
Figure 5. Track Pad.
Figure 6. Track Installation.
Figure 7. Chain Link Bushing.
Figure 9. Adjusting Strap.
Figure 10. Slack.
Figure 11. Adjusting Track Length.
WHEEL AND TIRE ASSEMBLY REPLACEMENT
Figure 1. Wheel and Tire Assembly.
WHEEL AND TIRE ASSEMBLY REPLACEMENT - Continued
TRACK REPLACEMENT
Figure 1. Cover.
Figure 2. Adjuster.
TRACK REPLACEMENT - Continued
Figure 3. Track.
Figure 4. Track.
Figure 5. Torque Sequence.
Figure 7. Track Tension Check.
Figure 8. Adjuster.
Figure 9. Cover.
HYDRAULIC DRIVE MOTOR REPLACEMENT
Figure 1. Hydraulic Drive Motor.
Figure 2. Hydraulic Drive Motor.
HYDRAULIC DRIVE MOTOR REPLACEMENT - Continued
HYDRAULIC DRIVE MOTOR OIL SERVICE
Figure 1. Drain Position.
Figure 2. Fill Position.
TANDEM PUMP REPLACEMENT
Figure 1. Tandem Pump.
Figure 2. Tandem Pump.
Figure 3. Plate and Coupling.
Figure 4. Fittings.
Figure 5. Coupling Dimension.
Figure 7. Tandem Pump.
Figure 8. Tandem Pump.
TRACK FRAME ASSEMBLY MAINTENANCE
TRACK FRAME ASSEMBLY MAINTENANCE - Continued
Figure 1. Rubber Access Plug.
TRACK FRAME ASSEMBLY MAINTENANCE - Continued
Figure 3. Powertrain Lines and Fittings.
TRACK FRAME ASSEMBLY MAINTENANCE - Continued
Figure 4. Track Frame Assembly.
Figure 5. Access Cover.
Figure 6. Access Cover.
Figure 7. Track Frame Assembly.
Figure 8. Rubber Access Plug.
Figure 9. Powertrain Lines and Fittings.
Figure 10. Housing.
AUXILIARY HYDRAULIC CABLE REPLACEMENT
Figure 1. Auxiliary Hydraulic Cable.
AUXILIARY HYDRAULIC CABLE REPLACEMENT - Continued
BOOM OVERRIDE VALVE REPLACEMENT
Figure 1. Console Bracket.
Figure 2. Boom Override Valve.
BOOM OVERRIDE VALVE REPLACEMENT - Continued
HYDRAULIC HOSES, LINES AND FITTINGS REPLACEMENT
Figure 1. Clamps.
Figure 2. Line, Hose, and Fitting.
HYDRAULIC HOSES, LINES AND FITTINGS REPLACEMENT - Continued
Figure 3. Line, Hose, and Fitting.
Figure 4. Clamps.
JOYSTICK HOSES AND FITTINGS REPLACEMENT
JOYSTICK HOSES AND FITTINGS REPLACEMENT - Continued
Figure 1. Joystick Hoses and Fittings.
Figure 2. Joystick Hoses and Fittings.
JOYSTICK HOSES AND FITTINGS REPLACEMENT - Continued
CONTROL HANDLES AND JOYSTICK VALVE REPLACEMENT
Figure 1. Control Handle.
Figure 2. Joystick Valve.
Figure 3. Joystick Valve.
Figure 4. Control Handle.
CONTROL HANDLES AND JOYSTICK VALVE REPLACEMENT - Continued
AUXILIARY HYDRAULIC PEDAL REPLACEMENT
'TM 292-23.book' by mvalin - Page 692 of 1384
Figure 3. Auxiliary Hydraulic Cable.
Figure 4. Auxiliary Hydraulic Cable.
Figure 6. Auxiliary Hydraulic Cable.
LIFT CYLINDER MAINTENANCE
AUXILIARY HYDRAULIC PEDAL REPLACEMENT - Continued
Figure 2. Lift Cylinder Hoses and Lines.
Figure 3. Lift Cylinder Upper Pin.
Figure 4. Lift Cylinder Lower Pin.
Figure 5. Lift Cylinder.
Figure 6. Lift Cylinder.
AUXILIARY HYDRAULIC PEDAL REPLACEMENT - Continued
Figure 7. Lift Cylinder.
Figure 9. Lift Cylinder Lower Pin.
Figure 10. Lift Cylinder Upper Pin.
Figure 11. Lift Cylinder Hoses and Lines.
Figure 12. Lift Cylinder Cover.
TILT CYLINDER MAINTENANCE
Figure 1. Tilt Cylinder.
Figure 2. Tilt Cylinder.
Figure 3. Tilt Cylinder.
TILT CYLINDER MAINTENANCE - Continued
Figure 4. Tilt Cylinder.
GEAR PUMP MAINTENANCE
Figure 1. Gear Pump.
Figure 2. Gear Pump Disassembly.
GEAR PUMP MAINTENANCE - Continued
Figure 3. Gear Pump.
Figure 4. Gear Pump.
MAIN HYDRAULIC VALVE MAINTENANCE
Figure 1. Main Hydraulic Valve.
Figure 2. Main Hydraulic Valve.
Figure 3. Pressure Relief Valve.
Figure 4. Loader Spool.
Figure 5. Bucket Spool.
Figure 6. Auxiliary Spool.
Figure 7. Ports and Relief Valves.
MAIN HYDRAULIC VALVE MAINTENANCE - Continued
MAIN HYDRAULIC VALVE MAINTENANCE - Continued
Figure 8. Auxiliary Spool.
Figure 9. Bucket Spool.
Figure 10. Loader Spool.
Figure 11. Fittings.
Figure 12. Main Hydraulic Valve.
Figure 13. Main Hydraulic Valve.
Figure 14. Main Hydraulic Valve.
RAISING LOADER ARMS WITH ENGINE STOPPED AND NO ELECTRICAL POWER
Figure 1. Attachment Coupler and Loader Arm Hose Connections.
A/C CONDENSER REPLACEMENT
Figure 1. A/C Condenser.
A/C CONDENSER REPLACEMENT - Continued
A/C RECEIVER/DRYER REPLACEMENT
Figure 1. A/C Receiver/Dryer.
A/C RECEIVER/DRYER REPLACEMENT - Continued
A/C SYSTEM MAINTENANCE
A/C SYSTEM MAINTENANCE - Continued
Figure 1. Recovery Hook-Up.
A/C SYSTEM MAINTENANCE - Continued
Figure 2. Evacuation Hook-Up.
A/C SYSTEM MAINTENANCE - Continued
Figure 3. Charging Hook-Up.
RH/LH CONSOLE REPLACEMENT
Figure 1. RH Console.
Figure 2. RH Console Connectors.
Figure 3. LH Console.
Figure 4. LH Console Connectors.
Figure 5. RH Console Connectors.
Figure 6. RH Console.
CHASSIS COVERS REPLACEMENT
Figure 2. Chassis Cover (ROPS).
CHASSIS COVERS REPLACEMENT - Continued
Figure 4. Chassis Covers (Underside).
BATTERY ACCESS COVER REPLACEMENT
Figure 2. Battery Compartment Cover.
Figure 3. Battery Compartment Cover Retaining Cable.
Figure 4. Battery Compartment Cover Retaining Cable.
Figure 5. Battery Compartment Cover.
Figure 6. Battery Compartment Cover Screws.
COUNTERWEIGHT BUMPER REPLACEMENT
Figure 1. Counterweight Bumper Replacement.
COUNTERWEIGHT BUMPER REPLACEMENT - Continued
DATA PLATES AND WARNING LABELS REPLACEMENT
Figure 1. Data Plate.
HEAT SHIELD EXTENSION PANEL REPLACEMENT
Figure 2. Heat Shield Plate (Cab Interior).
Figure 3. Heat Shield Plate (Rear of ROPS).
Figure 5. Heat Shield Plate and Brackets.
HEAT SHIELD EXTENSION PANEL REPLACEMENT - Continued
Figure 6. Heat Shield Plate and Brackets.
Figure 7. Heat Shield Plate.
Figure 9. Heat Shield Plate (Cab Interior).
Figure 10. Heat Shield Pad (Rear of ROPS).
HEATER HOSES, VALVES, AND FITTINGS REPLACEMENT
Figure 1. Heater Hose Return.
Figure 2. Heater Hose Supply.
Figure 4. Heater ON/OFF Valve.
Figure 6. Electric Water Valve (Rear).
Figure 8. Cab Front.
Figure 10. RH Side Access.
Figure 11. RH Side Access.
Figure 13. Cab Front.
Figure 15. Electric Water Valve (Rear).
Figure 17. Heater ON/OFF Valve.
Figure 19. Heater Hose Supply.
HEATER HOSES, VALVES, AND FITTINGS REPLACEMENT - Continued
DUST BOOT REPLACEMENT - Continued
Figure 1. Dust Boot Removal.
LH JOYSTICK CONSOLE BRACKET REPLACEMENT
Figure 2. Bracket Plate.
Figure 3. Clamp and Hose Bracket.
Figure 4. LH Joystick Console Bracket.
Figure 5. LH Joystick Console Bracket.
Figure 6. Clamp and Hose Bracket.
Figure 7. Bracket Plate.
Figure 8. Bracket Mounting Bolts.
RH JOYSTICK CONSOLE BRACKET REPLACEMENT
Figure 2. Bracket Plate.
RH JOYSTICK CONSOLE BRACKET REPLACEMENT - Continued
Figure 4. Clamp and Hose Bracket.
Figure 6. Bracket Mounting Bolts.
LEFT JOYSTICK CONSOLE REPLACEMENT
Figure 2. Joystick Console Replacement.
LEFT JOYSTICK CONSOLE REPLACEMENT - Continued
RIGHT JOYSTICK CONSOLE REPLACEMENT
Figure 2. Power Point Wires.
RIGHT JOYSTICK CONSOLE REPLACEMENT - Continued
Figure 3. Power Point Wires.
Figure 4. Joystick Console Replacement.
LOADER ARM MAINTENANCE
Figure 1. Hydraulic Lines and Hoses.
Figure 2. Lift Cylinder.
Figure 3. Loader Arm Support.
Figure 4. Lifting Device.
Figure 5. Loader Arm.
Figure 6. Hoses.
Figure 8. Coupler.
Figure 9. Quick Disconnects.
LOADER ARM MAINTENANCE - Continued
Figure 11. Lines and Clamps.
Figure 12. Quick Disconnects.
Figure 13. Coupler.
Figure 14. Tilt Cylinder.
Figure 15. Hoses.
Figure 16. Lifting Device.
Figure 17. Loader Arms Support.
Figure 19. Lift Cylinder.
Figure 20. Hydraulic Lines and Hoses.
LOADER ARM SUPPORT STRUT REPLACEMENT
Figure 2. Loader Support Strut.
LOADER ARM SUPPORT STRUT REPLACEMENT - Continued
REAR WINDOW REPLACEMENT
Figure 2. Heat Shield Plate and Brackets.
Figure 4. Case, Drain Hoses, and Retaining Hardware.
Figure 6. Rear Window (Interior).
Figure 8. Rear Window Clip.
Figure 9. Rear Window Clip.
Figure 11. Rear Window (Interior).
Figure 13. Case, Drain Hoses, and Retaining Hardware.
Figure 15. Heat Shield Plate and Brackets.
REAR WINDOW REPLACEMENT - Continued
REFRIGERANT HOSES REPLACEMENT
Figure 2. HVAC Box Hoses.
Figure 3. Receiver/Dryer.
Figure 5. Outer Cover.
Figure 7. A/C Compressor.
Figure 9. Condenser.
REFRIGERANT HOSES REPLACEMENT - Continued
Figure 10. Condenser.
Figure 11. Clamp.
Figure 12. A/C Compressor.
Figure 13. Wiring Harness and Hoses.
Figure 15. Hoses.
Figure 16. Receiver/Dryer.
Figure 18. End Cap Covers and Retaining Hardware.
ROPS REPLACEMENT
Figure 1. ROPS.
ROPS REPLACEMENT - Continued
Figure 2. ROPS.
ROPS REPLACEMENT - Continued
ROPS ACCESS COVERS REPLACEMENT
Figure 1. ROPS Cover.
ROPS ACCESS COVERS REPLACEMENT - Continued
ROPS LATCH REPLACEMENT
Figure 1. ROPS Latch Replacement.
ROPS LATCH REPLACEMENT - Continued
ROPS PIVOT STRUTS REPLACEMENT
Figure 1. Exterior Nut.
Figure 2. RH ROPS Main Pivot Strut.
Figure 3. Exterior Bolts.
Figure 5. LH ROPS Auxiliary Pivot Strut Through Bolt (Lower End).
Figure 7. LH ROPS Auxiliary Pivot Strut Through Bolt (Lower End).
Figure 8. LH ROPS Auxiliary Pivot Strut (Upper End).
Figure 10. Exterior Bolts.
Figure 11. RH ROPS Main Pivot Strut.
Figure 12. Exterior Nut.
SEAT BELT REPLACEMENT
Figure 2. Lap Belt Retractor.
Figure 4. Shoulder Belt Retractor Spacer and Bolt.
SEAT BELT REPLACEMENT - Continued
Figure 6. Electrical Connector and Buckle.
Figure 8. Shoulder Belt Retractor.
Figure 10. Seat Belt Mounting.
ARM REST REPLACEMENT
ARM REST REPLACEMENT - Continued
Figure 2. Arm Rest Replacement.
REAR-VIEW MIRRORS REPLACEMENT
Figure 2. Mirror Assembly and Mounting Bracket.
Figure 3. Mirror Assembly and Mounting Bracket.
Figure 4. Left-Hand Rear-View Mirror.
SOUND SEALING REPLACEMENT
Figure 2. Machine Rear.
Figure 4. Inside Lower Front of Machine.
Figure 5. Inside Lower Front of Machine.
Figure 7. Machine Rear.
STEP REPLACEMENT
Figure 1. Step Replacement.
STEP REPLACEMENT - Continued
LOAD CAPACITY SIGN REPLACEMENT
Figure 1. Load Capacity Sign.
LOAD CAPACITY SIGN REPLACEMENT - Continued
Figure 2. Load Capacity Sign.
LH WINDOW REPLACEMENT
Figure 2. LH Console.
Figure 3. Left Side Window.
Figure 4. Left Side Window.
Figure 5. LH Console.
Figure 6. Seat Belt Mounting.
RH WINDOW REPLACEMENT
Figure 2. RH Console.
Figure 3. Right Side Window.
Figure 4. Right Side Window.
Figure 5. RH Console.
Figure 6. Upper Weapon Rack Installation.
TOP WINDOW REPLACEMENT
Figure 2. Top Window.
WEAPON RACK REPLACEMENT
Figure 2. Weapon Rack Replacement.
WEAPON RACK REPLACEMENT - Continued
Figure 3. ROPS Cover.
COUPLER MAINTENANCE
Figure 1. Coupler Removal.
Figure 2. Coupler Disassembly.
COUPLER MAINTENANCE - Continued
Figure 3. Coupler Assembly.
Figure 4. Coupler Installation.
REAR DOOR MAINTENANCE
REAR DOOR MAINTENANCE - Continued
Figure 1. Rear Engine Door.
Figure 2. Rear Engine Door.
SEAT ASSEMBLY MAINTENANCE
Figure 2. Electrical Connector and Support Strut.
Figure 3. Electrical Connector and Buckle.
Figure 4. Seat Assembly Mounting.
Figure 5. Seat Support.
Figure 7. Seat Mount.
Figure 9. Foam and Fasteners.
Figure 10. Wiring Harness.
Figure 12. Seat Support.
Figure 14. Tilting and Blocking Seat Assembly.
SEAT ASSEMBLY MAINTENANCE - Continued
THROTTLE CONTROLS REPLACEMENT
Figure 2. Throttle Control Rod Retaining Clamp.
Figure 4. Actuator-to-Pedal Linkage (Upper).
Figure 5. Setscrew.
Figure 7. Throttle Pedal.
Figure 8. Throttle Pedal.
Figure 9. Throttle Lever and Actuator Assembly.
Figure 11. Actuator-to-Engine Control Rod (Rear).
Figure 13. Actuator-to-Engine Control Rod (Front).
Figure 14. Setscrew.
Figure 15. Actuator-to-Engine Control Rod (Front).
CAB DOOR MAINTENANCE
Figure 2. Wiper Blade.
Figure 4. Wiper Motor and Bracket.
Figure 6. Latch Cover.
Figure 8. Friction Catch Stud.
Figure 10. Door Handle, Gaskets, and Spacers.
Figure 12. Ball Stud.
Figure 14. Door Switch.
CAB DOOR MAINTENANCE - Continued
Figure 15. Front Door.
Figure 17. Cylinder.
Figure 19. Door Handle (Interior).
Figure 21. Right Thumb Rotary Latch.
Figure 23. Wiper Motor and Bracket.
Figure 25. Wiper Arm.
Figure 27. Wiper Motor Wiring Harness.
WINDSHIELD WASHER RESERVOIR REPLACEMENT
Figure 2. Windshield Washer Reservoir.
Figure 4. Reservoir Bracket.
Figure 6. Washer Hose and Nozzle.
Figure 7. Reservoir Bracket.
Figure 9. Windshield Washer Reservoir.
WINDSHIELD WASHER RESERVOIR REPLACEMENT - Continued
DELUXE HEATER A/C MAINTENANCE
Figure 1. End Cap Covers and Retaining Hardware.
Figure 2. A/C Hose Connections on Evaporator.
Figure 4. Wiring Harness, Heater Hoses, Drain Hose, and Retaining Hardware on Back of ROPS.
Figure 5. Case, Drain Hoses, and Retaining Hardware.
DELUXE HEATER A/C MAINTENANCE - Continued
Figure 7. Deluxe Heater A/C Assembly.
DELUXE HEATER A/C MAINTENANCE - Continued
Figure 8. A/C Evaporator Core and Heater Core.
DELUXE HEATER A/C MAINTENANCE - Continued
Figure 9. A/C Evaporator Core and Heater Core.
DELUXE HEATER A/C MAINTENANCE - Continued
Figure 10. Deluxe Heater A/C.
Figure 11. Deluxe Heater A/C Assembly Installation.
Figure 13. O-rings on A/C Hose Fittings.
Figure 15. End Cap Covers and Retaining Hardware.
Figure 16. Wiring Harness, Heater Hoses, Drain Hose, and Retaining Hardware on Back of ROPS.
ENGINE COMPARTMENT HOOD REPLACEMENT
ENGINE COMPARTMENT HOOD REPLACEMENT - Continued
Figure 1. Engine Compartment Hood.
Figure 2. Engine Compartment Hood Hardware.
Figure 3. Engine Compartment Assembly.
ENGINE COMPARTMENT HOOD REPLACEMENT - Continued
EXHAUST EXTENSION TUBE REPLACEMENT
Figure 1. Exhaust Pipe.
EXHAUST EXTENSION TUBE REPLACEMENT - Continued
HEADLINER DUCT ASSEMBLY MAINTENANCE
Figure 2. Headliner Duct Assembly.
Figure 4. Dome Light and Bezel.
Figure 6. Dome Light and Lens.
Figure 8. Round Vent, Bezel, and Headliner.
Figure 9. Rectangular Vent and Headliner.
Figure 10. Dome Light and Headliner.
Figure 12. Dome Light and Bulb.
Figure 14. Rectangular Vent and Headliner.
Figure 15. Round Vent, Bezel, and Headliner.
Figure 16. Headliner Duct Assembly.
Figure 18. Interior Cab Mirrors.
ROPS TILTING OPERATION
Figure 2. ROPS Bolts.
Figure 4. ROPS Tilting.
Figure 5. ROPS Latch Lever.
Figure 6. Closing ROPS.
Figure 7. ROPS Bolts.
A/C SWITCH REPLACEMENT
Figure 1. A/C Switch.
A/C PRESSURE SWITCH REPLACEMENT
Figure 1. Floor Plate.
A/C PRESSURE SWITCH REPLACEMENT - Continued
AIR FILTER RESTRICTION SWITCH REPLACEMENT
Figure 1. Air Filter Restriction Switch.
AIR FILTER RESTRICTION SWITCH REPLACEMENT - Continued
COOLANT TEMPERATURE SENSOR REPLACEMENT
Figure 1. Coolant Temperature Sensor.
COOLANT TEMPERATURE SENSOR REPLACEMENT - Continued
BACKUP ALARM REPLACEMENT
Figure 1. Backup Alarm.
BACKUP ALARM PRESSURE SWITCH REPLACEMENT
BACKUP ALARM PRESSURE SWITCH REPLACEMENT - Continued
Figure 2. Backup Alarm Pressure Switch.
BATTERIES REPLACEMENT
Figure 1. Battery Compartment.
Figure 2. Battery Compartment.
BATTERIES REPLACEMENT - Continued
BATTERY POWER DISCONNECT
Figure 1. Battery Compartment.
BATTERY POWER DISCONNECT - Continued
BATTERY CABLES REPLACEMENT
Figure 1. Battery Cables and Single-Point Power Distribution Block.
Figure 2. NATO Plug Connection.
Figure 4. 100 Amp Fuse.
Figure 6. Battery Cables and Single-Point Power Distribution Block.
Figure 7. 100 Amp Fuse.
Figure 9. Power Equalizer Connections.
BATTERY CABLES REPLACEMENT - Continued
BLOWER SWITCH REPLACEMENT
Figure 1. Blower Switch Knob.
BLOWER SWITCH REPLACEMENT - Continued
CAB WIRING HARNESS REPLACEMENT
Figure 1. ROPS Bolts Removal.
Figure 3. Access Cover.
Figure 5. Bulkhead Connectors.
Figure 6. Cab Wiring Harness (RH Leg).
Figure 7. Cab Wiring Harness (LH Leg).
Figure 8. ROPS Interior Front.
Figure 9. ROPS Front Interior.
Figure 10. Cab Wiring Harness (LH Leg).
Figure 11. Cab Wiring Harness (RH Leg).
Figure 12. Bulkhead Connectors.
Figure 14. Access Cover.
Figure 16. ROPS Bolts Installation.
CHASSIS WIRING HARNESS REPLACEMENT
Figure 1. Rear Access Doors.
Figure 2. Fuel Sender Wiring.
Figure 3. Rear Door Chassis Wiring.
Figure 4. Horn Wiring.
Figure 6. Hydraulic Pump Wiring.
Figure 7. Fuse Panel.
Figure 8. Left Joystick Support.
Figure 9. Left Joystick Support Connection.
Figure 11. Left Joystick Support Connection.
Figure 12. Brake Pilot Valve Connections.
Figure 14. Occupant Presence Switch Connection.
Figure 16. Single Point Power Distribution Block Connection.
Figure 18. Hydraulic Filter Connection.
Figure 20. Hydraulic Filter Connection.
Figure 21. Single Point Power Distribution Block Connection.
Figure 23. Right Hand Joystick Connection.
Figure 25. Chassis Harness Connections.
Figure 27. Left Joystick Support Connection.
Figure 28. Protective Cover.
Figure 30. Left Joystick Support.
Figure 31. Fuse Panel.
Figure 32. Hydraulic Pump Wiring.
Figure 33. Rear Door Chassis Wiring.
Figure 34. Horn Wiring.
Figure 36. Fuel Sender Wiring.
Figure 37. Rear Access Doors.
DOOR AND JUMPER WIRING HARNESS REPLACEMENT
Figure 1. Front Access Door Jumper Wiring.
Figure 2. Floor Access Plate.
Figure 3. Windshield Washer Reservoir Wiring.
Figure 4. Floor Access Plate.
Figure 5. Front Access Door Jumper Wiring.
ENGINE OIL PRESSURE SENSOR REPLACEMENT
Figure 1. Engine Oil Pressure Sensor.
ENGINE OIL PRESSURE SENSOR REPLACEMENT - Continued
ENGINE WIRING HARNESS REPLACEMENT
Figure 2. Engine Wiring Harness Connector.
Figure 3. Clamps.
Figure 4. Alternator Wiring.
Figure 5. Engine Ground Stud.
Figure 7. Air Filter Restriction Sensor Connector.
Figure 9. Coolant Temperature Sending Unit (Parts Removed for Clarity).
Figure 10. Coolant Temperature Sending Unit (Parts Removed for Clarity).
Figure 11. Electrical Connector at Fuel Injection Pump.
Figure 13. Right Side Engine Wiring.
Figure 15. Alternator Wiring.
Figure 16. Clamps.
Figure 17. Engine Wiring Harness Connector.
Figure 18. Rear Access Doors.
FUEL LEVEL SENDER REPLACEMENT
Figure 1. Fuel Level Sender.
FUEL LEVEL SENDER REPLACEMENT - Continued
FUEL INJECTION PUMP WIRING HARNESS REPLACEMENT
Figure 1. Fuel Injection Pump Wiring Harness Removal.
FUEL INJECTION PUMP WIRING HARNESS REPLACEMENT - Continued
HORN REPLACEMENT
Figure 1. Horn.
Figure 2. Horn.
HVAC TEMPERATURE CONTROL SWITCH REPLACEMENT
Figure 1. HVAC Temperature Control Switch.
HVAC TEMPERATURE CONTROL SWITCH REPLACEMENT - Continued
HVAC AND A/C CLUTCH WIRING HARNESSES REPLACEMENT
Figure 1. HVAC Wiring Harness Connector.
Figure 2. Cover Removal.
Figure 3. HVAC Wiring Harness.
Figure 5. Floor Plate.
Figure 6. ROPS Bolts Removal.
Figure 8. HVAC Wiring Harness.
Figure 10. HVAC Wiring Harness.
Figure 11. Friction Catch Stud.
Figure 13. Floor Plate.
Figure 15. HVAC Wiring Harness.
Figure 16. Cover Installation.
Figure 17. HVAC Wiring Harness Connector.
Figure 18. AC Clutch Connector.
Figure 19. AC Clutch Connector.
Figure 20. HVAC Wiring Harness and A/C Clutch Harness Leads.
INSTRUMENT PANEL REPLACEMENT
Figure 2. Back of Instrument Panel.
INSTRUMENT PANEL REPLACEMENT - Continued
NATO SLAVE RECEPTACLE REPLACEMENT
Figure 1. Battery Compartment.
NATO SLAVE RECEPTACLE REPLACEMENT - Continued
POWER EQUALIZER (12-TO-24V) REPLACEMENT
Figure 1. Battery Compartment.
POWER PLUG OUTLET REPLACEMENT
Figure 2. Power Plug Outlet.
POWER PLUG OUTLET REPLACEMENT - Continued
Figure 3. Power Plug Outlet.
Figure 4. Joystick Console.
CHARGING SYSTEM PROTECTION RESISTOR REPLACEMENT
Figure 1. Engine Compartment.
SINGLE POINT POWER DISTRIBUTION BLOCK REPLACEMENT
Figure 1. Engine Compartment.
GRID HEATER AND STARTER RELAYS REPLACEMENT
Figure 1. Grid Heater and Starter Relays.
GRID HEATER AND STARTER RELAYS REPLACEMENT - Continued
HYDRAULIC OIL TEMPERATURE SENDER REPLACEMENT
HYDRAULIC OIL TEMPERATURE SENDER REPLACEMENT - Continued
Figure 2. Hydraulic Oil Temperature Sender.
REAR (TAIL) POSITION LAMP MAINTENANCE
Figure 1. Rear (Tail) Position Lamp.
Figure 3. Rear (Tail) Position Lamp.
Figure 5. Rear (Tail) Position Lamp.
FRONT/SIDE WORK LIGHTS REPLACEMENT
Figure 1. Front Work Light.
FRONT/SIDE WORK LIGHTS REPLACEMENT - Continued
REAR WORK LIGHT REPLACEMENT
Figure 1. Rear Work Light.
WORK LIGHTS SWITCH REPLACEMENT
Figure 2. Work Lights Switch Connector.
Figure 4. RH Console.
AUGER REPAIR
Figure 1. Auger Drive Removal.
Figure 2. Auger Hoses and Mounting Removal.
AUGER REPAIR - Continued
Figure 3. Auger Hoses and Mounting Installation.
Figure 4. Auger Drive Installation.
ATTACHMENT CONTAINER REPAIR
Figure 2. Ratchet-Type Strap.
Figure 3. Access Door and Mounting Screws.
ATTACHMENT CONTAINER REPAIR - Continued
HAMMER REPAIR
Figure 1. Hoses and Fittings.
Figure 3. Gas Valve Assembly.
Figure 4. Hammer Assembly.
Figure 5. Hammer and Bracket.
Figure 6. Hammer and Frame.
Figure 8. Gas Valve Assembly.
Figure 10. Hose Cushion.
Figure 11. Hoses.
Figure 12. Inlet Fitting and Cap.
Figure 14. Charging Hammer.
Figure 15. Gas Valve Assembly.
PALLET FORKS REPAIR
Figure 2. Tine Removal.
Figure 3. Locking Lever.
Figure 5. Locking Lever Assembly.
PALLET FORKS REPAIR - Continued
Figure 6. Spring and Pin Assembly.
Figure 7. Locking Lever and Roll Pin Installation.
Figure 8. Pallet Fork Assembly.
BUCKET REPAIR
Figure 1. Hydraulic Cover.
Figure 2. Bucket Hoses.
Figure 3. Upper Cylinder.
Figure 4. Cylinder Hoses.
Figure 6. Clamshell Pivot Pin.
Figure 8. 90 Elbows.
Figure 9. 90 Elbows.
Figure 11. Clamshell Pivot Pin.
Figure 13. Cylinder Hoses.
Figure 15. Bucket Hoses.
BUCKET REPAIR - Continued
MECHANICAL GENERAL MAINTENANCE INSTRUCTIONS
RELIEVING HYDRAULIC SYSTEM PRESSURE
RELIEVING HYDRAULIC SYSTEM PRESSURE CONTINUED
CLEANING INSTRUCTIONS
CLEANING AND FLUSHING HYDRAULIC SYSTEM
Cleaning Hydraulic System
Flushing Water from Hydraulic System
CLEANING HYDROSTATIC SYSTEM
CLEANING HOSES, TUBES, AND FITTINGS
INSPECTION INSTRUCTIONS
REPAIR INSTRUCTIONS CONTINUED
STANDARD TOOL REQUIREMENTS
FLUID DISPOSAL
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS
Figure 1. Splicing Wires.
Figure 2. Ring Terminal Repair.
Figure 3. Military Connector Repair.
MULTIMETER USAGE
RELAY INSPECTION AND TESTING
OPEN HARNESS TEST
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
OPEN HARNESS TEST - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
Table 3. 37 Degree Flare Fitting.
Table 4. Straight Thread with O-Ring.
Table 6. O-Ring Face Seal End.
Table 8. Pipe Fitting.
SCHEMATICS
Component Specifications.
Connector Parameter Namin Convention
Color Abbreviations
HVAC
Handle Connections
Engine, Starting and Charging System
Engine - KSB Cold Start Circuit
Power Center
Power Center
Bulkhead Connections
RH Console
Frame 19. Miscellaneous Circuits.
Backup Alarm
Chassis Harness Splices
Chassis Harness Splices
Cab Harness Splices
Door Harness
Lights
LH Console
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
REFERENCES - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 1. Maintenance Allocation Chart (MAC) for Skid Steer Loader - Continued.
Table 2. Tools and Test Equipment for the Skid Steer Loader.
Table 2. Tools and Test Equipment for the Skid Steer Loader - Continued.
Table 3. Remarks for the Skid Steer Loader.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business
