Gehl RT135 RT165 Manitou Mustang 1350RT 1650RT Compact Track Loaders Service Manual 50950470 – PDF

Gehl RT135 RT165 Manitou Mustang 1350RT 1650RT Compact Track Loaders Service Manual 50950470 – PDF DOWNLOAD

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Gehl RT135 RT165 Manitou Mustang 1350RT 1650RT Compact Track Loaders Service Manual 50950470 – PDF DOWNLOAD

Language : English
Pages : 278
Downloadable : Yes
File Type : PDF
Size: 118 MB

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Gehl RT135 RT165 Manitou Mustang 1350RT 1650RT Compact Track Loaders Service Manual 50950470 – PDF DOWNLOAD

INTRODUCTION:

• With correct maintenance and proper use, compact track loaders will give years of dependable service.
  This service manual is intended to be a guide in the assembly and disassembly, installation and removal,
  adjustment and testing, troubleshooting and replacement of components that together make up the track
  loaders.
• In many of the procedures found within, the installation steps are the exact opposite of the removal steps,
  and therefore the opposite procedure is not written. Instead, a note to reverse the procedure is stated. This
  reduces redundancy and excessive pages in the manual. In cases though, where the assembly and
  disassembly or removal and installation procedures differ, and additional steps or safety concerns are
  paramount, the entire reverse procedure is written to include the additional information.
• The Table of Contents and the Index can be used to make finding a procedure easier. Many schematics,
  photographs and line art drawings are used to help perform the necessary repairs, tests and adjustments
  that the skid-steer loader needs to keep it in good running condition.
• If you have any questions, please contact your authorized dealer, or call the Manitou Service Department
  for assistance.

TABLE OF CONTENTS:

Gehl RT135 RT165 Manitou Mustang 1350RT 1650RT Compact Track Loaders Service Manual 50950470 – PDF DOWNLOAD

INTRODUCTION 2
This Page Intentionally Left Blank 8
TABLE OF CONTENTS 3
SPECIFICATIONS 9
SAFETY 11
General Information 11
Signal Words 11
DANGER 11
WARNING 11
CAUTION 11
Additional Safety Reminders 11
Mandatory Safety Shutdown Procedure 13
Lift Arm Support Device 13
WARNING 13
Lift Arm Support Device Engagement 13
1 Remove attachment from lift arm 13
2 Raise the lift arm fully 13
3 Turn keyswitch to OFF position to stop engine 13
4 Have an assistant remove the lift arm support device from its storage location on the left side of the machine Remove the lynch pin holding the support device up against the lift arm Allow the support device to come down into contact with the li 13
5 Restart the engine 13
6 Use the lift control to raise the lift arm until the support device drops over the end of the lift cylinder and around the cylinder rod Slowly lower the lift arm until the free-end of the support device contacts the top end of the lift cylinder 13
7 Look to be sure the support device is secure against the cylinder end Then, stop the loader engine, remove the key and leave the operator’s compartment 13
8 Stop the engine, and exit the machine 13
Lift Arm Support Device Disengagement 14
WARNING 14
1 Raise the lift arm fully 14
2 Turn the keyswitch to the OFF position to stop the engine and remove the key 14
WARNING 14
3 To store the lift arm support device, have an assistant raise it up until it contacts the lift arm Reinstall the lynch pin through the welded steel post on the lift arm 14
ROPS/FOPS – Raising 14
1 The lift arm should be either fully lowered or locked in the raised position per the “Lift Arm Support Device Engagement” procedure in this chapter 14
2 Turn the keyswitch to the OFF position to stop the engine Remove the key and take it with you 14
3 Leave the operator’s compartment 14
WARNING 14
4 Remove one hex nut, washer and capscrew on each side of the ROPS/FOPS lower corners 14
5 Grip the front grab handles at the front of the ROPS/FOPS and push up and back until the self- actuating lock mechanism engages The lock mechanism locks the ROPS/FOPS in a tilted-back position 14
IMPORTANT 15
ROPS/FOPS – Lowering 15
NOTE: 15
1 Slightly raise the ROPS/FOPS until tension on the ROPS/FOPS lock mechanism releases 15
2 Return the self-actuating lock mechanism to the unlocked position 15
3 Grip the front grab handles and pull down on the ROPS/FOPS to lower The ROPS/FOPS will lower slowly 15
IMPORTANT 15
4 Be sure control handles clear the ROPS/FOPS 15
5 Reinstall the two capscrews, nuts and flat washers that secure the ROPS/FOPS forward uprights to the chassis 15
Relieving Hydraulic Pressure – T-Bar Controls – Lift/Tilt/Auxiliary (RT165/1650RT Only) 15
1 Remove attachment from lift arm and lower the lift arm to the lift arm stops Be sure the hitch is level on the ground 15
2 Turn the keyswitch to the “OFF” position to shut off the engine 15
3 With the operator in the seat and the restraint bar lowered, turn the keyswitch to the “ON” position, but DO NOT start the engine 15
4 Move the lift, tilt and auxiliary hydraulics controls through several cycles 15
Relieving Hydraulic Pressure – Dual Joystick, Dual Hand and Hand/Foot Controls – Lift/Tilt/Auxiliary 16
1 Remove attachment from lift arm and lower the lift arm to the lift arm stops Be sure the hitch is level on the ground 16
2 Turn the keyswitch to the “OFF” position to shut off the engine 16
3 With the operator in the seat and the restraint bar lowered, turn the keyswitch to the “ON” position, but DO NOT start the engine 16
4 Depress the float switch to relieve pressure in the lift circuit 16
5 Actuate the standard auxiliary function This will relieve pressure in the lift and auxiliary circuit 16
6 The tilt circuit should have minimal pressure because the hitch rests on the ground 16
Note: 16
CAUTION 16
Loader Raising Procedure 17
WARNING 17
WARNING 17
1 To raise and block the track loader, obtain enough suitable blocks of sufficient strength and stability to support the loader 17
2 Using a jack or hoist capable of raising the fully- equipped loader (with all attached options), lift the loader until the tracks are off the ground 17
3 Place the blocks under the flat part of the loader chassis Place them parallel with, but not touching, the tracks 17
4 Slowly lower the loader so that its weight rests on the blocks 17
5 When the procedure is finished, the tracks will be off the ground, and can be removed as necessary 17
Loader Lowering Procedure 17
1 Using a jack or hoist, raise the loader until its weight no longer rests on the reinforced blocks 17
2 Carefully remove the reinforced blocks under the loader 17
3 Slowly lower the loader until the tracks are on the ground 17
CHAPTER NOTES 18
LUBRICATION 19
WARNING 19
IMPORTANT 19
Hydraulic Oil Reservoir 19
Visual Hydraulic Oil Level Indicator 19
Hydraulic Oil Drain RT165/1650RT shown,; others similar 19
Hydraulic Filter Location 20
NOTE: 20
Crankcase Oil 20
Engine Oil Dipstick 20
Remote Engine Oil Drain 20
NOTE: 20
Remote Engine Oil Filter 21
Grease Fitting Locations 21
1 Grease the hitch latch pin, tilt cylinder and attachment grease cap pivots 21
Hitch Latch and Attachment Pivot Pins 21
1 Grease two lift cylinder pivots 21
Lift Cylinder Base End 21
Lift Cylinder Rod End 21
2 Grease the lift arm pivots 22
Lift Arm Pivot 22
Cooling System Drain Procedure 22
WARNING 22
1 Raise the engine cover and lock open the rear grille 22
2 Unlock the radiator latch at the right lower side of the radiator and swing the radiator outward 22
3 Place a catch pan with a capacity of at least 5 0 gallons (19 L) underneath the chassis, below the radiator drain plug 22
4 Remove the radiator drain plug underneath the radiator 23
Radiator Drain Plug 23
5 Remove the pressurized radiator cap at the top of the radiator 23
6 Fully open the drain plug of the radiator to drain the anti-freeze 23
7 Retighten the drain plug on the radiator when it is finished draining 23
8 Reference “SPECIFICATIONS” on page 1 for the engine coolant capacities Add a mixture of 50% water and 50% ethylene glycol to the radiator 23
9 Retighten the pressurized radiator cap 23
1 Raise the engine cover and lock open the rear grille 23
2 Unlock the radiator latch at the right lower side of the radiator and swing the radiator outward 23
3 Remove the fill cap on the hydraulic reservoir and install a wet/dry Shop•Vac hose into the tube 23
NOTE: 23
4 On the cooler side, remove the top hydraulic hose from its fitting on the oil cooler and plug/cap the hose and cooler port 23
5 Disconnect the tube attached at the hydraulic oil filter and plug/cap the tube and filter port 23
NOTE: 23
6 Turn the vacuum ON to lessen the amount of hydraulic oil leakage for this procedure 23
7 Place a catch pan below the lower cooler connection Unscrew the tube fitting at the lower cooler port and plug/cap the tube fitting Turn the vacuum OFF 23
Lower Cooler Port Tube 23
8 After the oil has drained from the cooler, place plugs/caps in the upper and lower ports, or reinstall the hoses and tube 23
CHAPTER NOTES 24
CHASSIS 25
Engine Access Cover – Removal and Installation 29
WARNING 29
1 Open the rear grille and lock it open 29
2 Open the engine access cover until the gas springs are completely extended 29
3 If equipped with air conditioning, disconnect the condensor fan electrical connectors 29
CAUTION 29
4 Disconnect the gas spring(s) from the engine access cover by removing the gas spring clips at both ends of the gas springs (HVAC) or by using a small screwdriver to pop the retaining clip off the ball stud on each end 29
5 Remove two nuts and spacers securing the engine access cover to the chassis Using a plastic hammer, tap one of the cover bolts out of the chassis just far enough to drop one side of the cover and then pull the other side off its bolt and remove t 29
6 Re-seat the bolt hammered in the previous step 29
ROPS/FOPS Removal and Installation 33
WARNING 33
1 Remove the engine access cover per the procedure in this chapter 33
2 Inside the engine compartment and forward of the fuse bank, disconnect two electrical harnesses If backup camera or HVAC equipped, all the lines need to be removed too, but the freon must be evacuated and the coolant drained before removing HVAC 33
3 Raise the ROPS/FOPS per the procedure in the Safety chapter of this manual 33
4 With the ROPS/FOPS tilted back and locked, attach a hoist so that it is supporting the weight of the ROPS/FOPS 33
Important: 33
WARNING 33
1 Remove a ground cable attached at the right side 33
2 Carefully remove the hardware that attaches the gas springs to the ROPS/FOPS 33
3 On each side, remove the capscrew securing the ROPS/FOPS pivot to the frame 33
4 Lift the ROPS/FOPS off the loader 34
Seat Removal and Installation 34
WARNING 34
1 Remove four nuts from the studs attaching the seat to the seat pan underneath the ROPS/FOPS 34
2 Release the lock mechanism and lower the ROPS/ FOPS 34
3 Slide the seat forward and disconnect the seat switch from the wiring harness 34
4 If there is a three-point restraint seat belt, remove the capscrew and locknut attaching the seat to the restraint belt on the left side 34
5 Lift the seat from the seat pan 34
Seat Slide Replacement 35
1 Remove the seat per the procedure in this chapter 35
2 Remove the four screws attaching the seat slides to the seat 35
Standard Seat 35
Air Suspension Seat 35
3 Replace with new slides using the existing screws 35
Side Console Removal and Installation 35
1 On the outside of the machine, remove the screws securing the forward side consoles to the ROPS/ FOPS 35
2 Pull the console away from ROPS/FOPS 35
Air Duct Louver Replacement 36
1 Using a thin flat-tipped screwdriver, insert the screwdriver between the face of the louver and the louver’s bezel 36
2 Rotate the screwdriver to lift the face and pop it off the bezel to release the louver 36
3 Pop new louver into existing bezel until a “click” sound indicates it is seated 36
ROPS/FOPS Rear Window Removal and Installation 36
WARNING 36
1 Grab and pull emergency exit tag until the ripcord pulls free of rubber seal 36
2 With an assistant outside the ROPS/FOPS to catch the window, push window outward 36
3 Slowly pull weatherstrip away from window frame 37
Weatherstrip 37
1 Recommended but not required: Mix a solution of 10% liquid dish soap and 90% water in a spray bottle 37
NOTE: 37
L-Hook 37
2 Apply soap solution to window, weatherstrip and metal frame surfaces 37
3 Start at top of window frame and install weatherstrip with the ripcord lip facing inside the ROPS/ FOPS and the glass lip facing out 37
4 Spray soap solution between glass window and inside edge of rear window 37
5 Carefully use the L-hook tool between glass and weatherstrip and work it underneath the glass Lift the glass lip over the weatherstrip Use caution to avoid breaking the glass 37
6 Use the pigtail hook tool to “pull down” the weatherstrip seal on the outside of the ROPS/FOPS to secure the window 37
7 On the inside of the ROPS/FOPS, install the ripcord in the ripcord lip, starting at top of weatherstrip Be sure to have emergency exit tag slipped over the ripcord before performing this step 37
8 Using L-hook tool, secure the ripcord in the ripcord lip by “pulling down” the lip over the cord 37
9 Test the window for security and mating of all seals 37
Restraint Bar Removal and Installation 39
1 Remove the plastic covers at the attachment locations of the restraint bar to the ROPS/FOPS 39
2 Beneath the foam cover, unplug the restraint bar switch wire from the ROPS/FOPS wire harness 39
3 Unclip the gas spring from its ball stud, attached at the restraint bar 39
4 Remove the hardware attaching the restraint bar to the rear deck of the ROPS/FOPS 39
5 Remove from the restraint bar assembly from the ROPS/FOPS 39
NOTE: 39
All-Tach® and Power-A-Tach® Hitch Removal and Installation 42
1 Power-A-Tach hitch machines: Using a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent, raise the lift arm high enough to access the single hydraulic cylinder hose lines on the hitch 42
WARNING 42
2 Power-A-Tach hitch machines: Disconnect the two hydraulic hoses from their fittings on the left side of the lift arm crossmember 42
NOTE: 42
NOTE: 42
3 Restart the machine, lower the lift arm and slightly extend the two tilt cylinders 42
NOTE: 42
4 Remove two capscrews and locknuts securing the lower tilt cylinder pivot pins While supporting the tilt cylinders, drive the pins out of their mounts 42
5 Using a flat-tip screwdriver, pry the grease cap off the lift arm on both sides 42
6 Remove two capscrews and locknuts securing the hitch to the lift arm, then drive the pivot pins out of the hitch and remove the hitch with the hoist 42
7 Retain two shim washers found between the hitch and lift arm 42
WARNING 43
Lift Arm Removal and Installation 46
1 Lower the lift arm 46
2 Remove the bucket or attachment from the loader 46
3 Remove the hitch (if replacing) per the procedure in this chapter 46
WARNING 46
4 Secure the lift arm with a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent 46
NOTE: 46
NOTE: 46
5 Disconnect hoses from their tubes at the rear of the lift arm On high-flow units there are additional high-flow hoses and tubes to disconnect on the right side 46
Left Rear Lift Arm Hoses 46
Right Rear Lift Arm Hoses 46
6 Remove a capscrew and locknut securing the rod end of the lift cylinder pivot pin to the lift arm 46
Lift Cylinder Pivot Pin 46
7 While supporting the lift cylinder, remove the lift cylinder pin from the lift arm Repeat for the other side 46
WARNING 46
8 Disconnect tilt cylinder hoses from lift arm crossmember tubes, either on top of or behind the lift arm crossmember 47
9 Remove both tilt cylinders from the lift arm per the procedure in the Hydraulics System chapter 47
10 Remove two capscrews and locknuts securing a cover plate to the top of the lift arm crossmember 47
11 Remove fastening hardware securing the tilt tubes to the crossmember 47
12 Remove the capscrew and locknut that secures the lift arm pivot pin to the chassis Repeat for the other side 47
13 Drive the lift arm pivot pins out of the chassis 47
WARNING 47
14 If possible, use a hoist to move the lift arm onto a raised platform for better access to hydraulic tubes and fastening hardware 47
15 On the left and right sides of the lift arm, remove the fastening hardware securing the hydraulic tubes to either the side or underneath the lift arm, if necessary 47
16 Remove the cover plate on the couplers (f so equipped) at the front of the lift arm on both sides of the lift arm (if so equipped) 48
RT165/1650RT shown, others similar 48
17 Disconnect the couplers from their tubes and remove the couplers 48
18 If replacing the lift arm, remove the lift arm support device fastening hardware and remove the support device 48
NOTE: 48
NOTE: 48
Lift Arm Bushing Replacement 49
WARNING 49
1 If replacing the lower lift arm bucket pivot bushings, remove the hitch per the procedure in this chapter 49
2 If replacing lift arm bushings, remove the lift arm per the procedure in this chapter 49
WARNING 49
3 Use a punch to drive out bushings There are four upper lift arm composite bushings (two on each side) and two spring bushings used (one on each side) on the lower lift arm 49
Upper Lift Arm Bushing 49
Lower Lift Arm Bushing 49
4 Clean inside the opening to provide a smooth surface for installation of the new bushings 49
5 Apply Loctite® 680 or equivalent compound to the new lift arm bushings 49
6 Press new bushings into place or use a rubber mallet to drive them into the lift arm or links 49
7 Reinstall the hitch or the lift arm on the loader per the procedures in this chapter 49
Lift Arm Stop Installation and Adjustment 50
NOTE: 50
1 Lower the lift arm and measure the gaps between the stops and the lift arm 50
NOTE: 50
2 Remove the bucket or attachment from the loader Raise the lift arm and engage the lift arm support device as described in the Safety chapter of this manual 50
3 Remove hardware securing the stop to the lift arm and remove 50
4 Install shim(s) and reinstall the stop with its hardware 50
5 Start engine and lower the lift arm Verify the gaps (if any) and repeat this procedure as needed 50
Control Console Removal and Installation 50
WARNING 50
1 Remove the rubber floor mat from the loader 50
2 Remove five capscrews and washers securing the control console assembly to the crossmember underneath 50
3 Push the rubber boots inside the control console openings 50
4 With a hammer and punch on one control handle, remove the roll pin securing the grip and allow the grip to hang 51
5 Carefully lift the control cover assembly up and over the control handles and out of the loader 51
6 Two recessed cutouts in the crossmember allow access to the control handle assemblies 51
1 Remove four screws securing the control handle tower covers on both the left and right control handles 51
2 Before lifting off the tower covers, pull the rubber boots up and over the control handles and remove them 51
3 Lift up and remove the tower covers to access the hydraulic lines in the control handle towers 51
Clean-Out Cover, Floor Plate and Kickplate Cover Removal and Installation 52
WARNING 52
1 Remove the control consoles per the procedure in this chapter, if necessary 52
2 If removing debris from the foot area or to access foot pedal cables on hand/foot loaders, remove three self-tapping screws on the kickplate cover at the front of the chassis 52
Kickplate Cover 52
3 T-Bar, Dual Hand and Dual Joystick Models: Inside the ROPS/FOPS, carefully pull up on and remove the rubber floor mat 52
4 T-Bar and Dual Joystick Models: Remove three capscrews securing the clean-out plate to the floor plate 52
5 T-Bar and Dual Joystick Models: Remove the remaining capscrews securing the floor plate to the chassis and carefully remove the floor plate, being sure not to damage the foot pedal throttle 52
6 Hand/Foot Models: Between the foot pedals, remove three capscrews securing the clean-out cover (or doghouse cover) and lift it out of the loader 52
7 Hand/Foot Models: Remove the remaining capscrews securing the floor plate to the chassis and pull the floor plate up from the rear to the front to expose the foot pedal hydraulic lines 52
NOTE: 52
NOTE: 52
Crossmember Removal and Installation 53
WARNING 53
1 Remove the control consoles per the procedure in this chapter 53
2 Remove the floor plate per the procedure in this chapter 53
3 Remove three locking capscrews securing the left and right ROPS/FOPS seal plates inside the chassis and remove the plates 53
ROPS/FOPS Seal Plate – Right Side Shown 53
4 Disconnect the track drive control handle hoses on top of the hydrostatic pump at their fittings 53
RT165/1650RT shown, others similar 53
NOTE: 53
NOTE: 53
Cap or plug the hydraulic hoses and fittings after disconnecting them to prevent fluid loss and contamination of the hydraulic system 53
5 Disconnect the lift and tilt control handle hoses where they connect to main control valve or hydraulic tubes or solenoid valve in the chassis 53
At Control Valve – RT165/1650RT shown 53
At Control Valve – RT135/1350RT shown 53
At Control Valve – RT165/1650RT shown 54
At Control Valve – RT135/1350RT shown 54
At Solenoid Valve – RT165/1650RT shown 54
At Solenoid Valve – RT135/1350RT shown 54
At Solenoid Valve – RT165/1650RT shown 54
At Solenoid Valve – RT135/1350RT shown 54
6 Disconnect the electrical connector in the control handles at the end of the wire 55
Handle Wire Connector 55
7 Remove the hardware securing the crossmember foam cover to the crossmember and lift the foam cover up and out of the loader, over the control handles 55
RT165/1650RT shown, others similar 55
8 Remove the capscrews securing the crossmember to the chassis 55
9 Using two people, carefully lift the crossmember with the control handles attached out of the chassis 55
NOTE: 55
WARNING 56
1 Remove the control console per the procedure in this chapter 56
2 Remove the floor plate per the procedure in this chapter 56
3 Outside the chassis, remove three capscrews on the two inner ROPS/FOPS panels 56
4 Disconnect the electrical connector in both control handles at the end of the wire 56
5 Disconnect the clevis assemblies on the lift and tilt control rods from the main control valve 56
6 Disconnect the rod ends of the track drive control rods from the pivot tube assembly underneath the crossmember 56
7 Remove the eight tapping capscrews securing the crossmember to the chassis 56
8 Using two people, carefully lift the crossmember with the control handles attached out of the chassis 56
NOTE: 56
Fuel Sensor Removal and Installation 57
WARNING 57
1 Drain fuel tank into a clean approved container Drain fuel below the sensor mounting 57
2 Unplug the sensor connector 57
3 Remove the screws securing the sensor, then remove the sensor and gasket from the tank 57
1 Clean old gasket adhesive off fuel tank 57
2 Install new gasket using Form-A-Gasket #765- 1211 (or equivalent) to seal sensor opening on fuel tank 57
3 Install the sensor in the fuel tank 57
4 Install the screws through the sensor into the fuel tank DO NOT OVERTIGHTEN 57
5 Reconnect the Deutsch connector to the harness 57
Rear Grille Removal and Installation 57
WARNING 57
1 Open the engine access cover, pull up on the rear grille latch and swing the rear grille fully open to its locked-open position 57
2 Disconnect the tail lights wire harness (and backup alarm harness, if so equipped) along the right side of the engine compartment and remove any securing cable ties 57
3 Support the rear grille with a suitable hoist of adequate capacity and a positive locking mechanism able to support the rear grille 57
4 Remove two cotter pins on two clevis pins fastening the rear grille to the chassis 58
5 Remove the rear grille from the chassis 58
Rear Grille Latch Removal and Installation 58
1 Open the engine access cover, pull up on the rear grille latch and swing the rear grille fully open to its locked-in position 58
2 Remove two carriage bolts and locknuts securing the latch to the rear grille 58
RT165/1650RT Models 58
RT135/1350RT Models 58
3 Remove the door latch from the rear grille 58
TRACK DRIVE 59
Rubber Track Removal and Installation 64
WARNING 64
1 With the machine running and the drive system not moving, remove tension cylinder stop cover on the side on the machine with the track to be replaced 64
2 With the machine running and the drive system not moving, open the engine compartment Press and hold the red lock button on the track tension service switch, press the top of the switch to set the track tension cylinders into the service (retract 64
3 When the track tension cylinders are in the service (retracted) position, shut off the machine 64
4 Raise the machine about 150 mm (6 0”) so the tracks are free to move 64
WARNING 64
5 Use a pry bar to pry/guide the old track at off the front idler wheel 64
6 Using a hoist of adequate capacity and a positive locking mechanism able to support the track or equivalent, lift/guide the old track off at the drive sprocket Remove the old track 64
1 Using a hoist of adequate capacity and a positive locking mechanism able to support the track or equivalent, lift the new track and manoeuver the track under the rear idler wheel at using a pry bar and your foot 65
IMPORTANT: 65
2 Place a block under the new track to hold the track against the bottom of the rear idler wheel 65
3 Using a hoist of adequate capacity and a positive locking mechanism able to support the track or equivalent, lift/ guide the new track onto the drive sprocket 65
IMPORTANT: 65
4 Using a pry bar and wedging blocks, pull/guide the new track over the front idler wheel and under the bottom rollers Carefully, direct an assistant to start the machine and direct the assistant to operate the track drive slowly forward/back to wo 65
WARNING 65
NOTE: 65
IIMPORTANT: 65
5 Be sure the new track is fully engaged around the idler and roller wheels, and in the drive sprocket, all the way around 65
6 Remove any wedging blocks that were used to guide the track 65
7 Remove the block placed under the track 65
8 Start the machine, open the engine compartment and press the bottom of the track tension service switch, to set the track tension cylinders into the operating (extended) position 65
9 Close the engine compartment 65
10 Once the track tension cylinder has returned to the operating (extended) position, reinstall the cylinder stop cover 65
11 Operate the track drive forward/back to ensure the track is properly seated Adjust track positioning, if necessary 65
12 Remove the blocking and lower the machine to the ground 65
Pontoon Assembly Removal and Installation – RT165/1650RT Only 65
WARNING 65
1 Remove the track on the side of loader being serviced per the procedure described in this chapter 65
2 Remove all hydraulic hoses connected to the travel motor and tensioner cylinder emanating from the chassis 65
NOTE: 66
3 Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the pontoon assembly or equivalent to the pontoon assembly Remove the locknuts (280 ft-lbs ) (380 N•m) attaching the pontoon assembly to the chassis 66
4 Pull the pontoon assembly away from the chassis 66
Travel Motor and Bogie Wheels Removal and Installation 66
WARNING 66
1 Remove the track on the side of loader being serviced per the procedure described in this chapter 66
2 On RT165/1650RT Models, remove the pontoon assembly on the side of loader being serviced per the procedure described in this chapter 66
3 On RT165/1650RT Models, place the entire pontoon assembly on a work bench, if possible 66
4 For the travel motor, remove the 10 socket-head capscrews (210 ft-lbs) (285 N•m) securing the motor to the assembly 67
5 Supporting the travel with a suitable hoist of adequate capacity and a positive locking mechanism able to support the travel motor or equivalent, pull the travel motor out of the pontoon assembly 67
6 Remove the capscrew and cylinder stop on the tensioner cylinder securing it to the pontoon assembly 67
7 Carefully pull the front idler wheel half out of the pontoon assembly and support the front idler wheel and tensioner cylinder with a suitable hoist of adequate capacity and a positive locking mechanism able to support the front idler wheel or equ 67
8 Remove the capscrews (360 ft-lbs) (488 N•m) on the large rear idler wheel and the bogie wheels and remove the wheels 67
Track Tensioner Adjustment Procedure 68
IMPORTANT 68
1 Start the machine, open the engine compartment and press the bottom of the track tension service switch, to set the track tension cylinders into the operating (extended) position 68
2 Once the track tension cylinder has returned to the operating (extended) position, reinstall the cylinder stop cover 68
3 Operate the track drive forward/back to ensure the track is properly seated Adjust track positioning, if necessary 68
4 Remove the blocking and lower the machine to the ground 68
CONTROLS 69
5 70
11, 13 70
4, 12, 14 70
4, 12, 14 70
1, 7, 10 70
2, 3, 6, 8, 9 70
2 70
3 70
Dual Joystick – RT165 shown, RT135 similar 70
Hand/Foot Controls 70
5 70
1, 6, 8, 9 70
11, 13 70
1, 7, 10 70
1, 7, 10 70
4, 12, 14 70
11, 13 70
T-Bar Controls 70
2, 3, 6, 8, 9 70
Control Handle Assembly (Both Control Handles) Removal and Installation 76
1 Remove the crossmember per the procedure in the Mainframe chapter 76
2 Disassemble the control handles on a workbench to replace parts as needed 76
Control Handle Removal and Installation – Electrical Auxiliary Grip – Dual Joystick Controls 76
WARNING 76
1 Loosen the ratchet handle on the lift/tilt joystick tower and tilt the right control handle forward 76
2 Pull the joystick boot up and off the joystick 76
3 Remove screws securing the tower cover to the tower and remove the cover 76
4 Disconnect the electrical connector in the control handle at the end of the wire Note the wire terminal connections for assembling the control handle if replacing the handle’s electrical cable 76
Right Handle Wire 76
5 Remove six hoses attached at the bottom of the joystick tower Mark the hoses with their corresponding port numbers for reinstallation 76
6 Remove four self-tapping thread screws securing the joystick to the drive stand 77
7 Pull the disconnected hoses down and out of the joystick tower 77
8 Pull the joystick up and out of the joystick tower and set the drive on top of the tower Loosen the locking hex nut and unscrew the grip from the joystick 77
Locking Hex Nut 77
9 Pull the connector out of the joystick tower 77
10 Remove the grip from the track loader 77
Control Handle Removal and Installation – Hand/Foot Controls 77
WARNING 77
1 Remove the control console per the procedure in the Mainframe chapter 77
2 Disconnect the electrical connector in the control handle at the end of the wire Note the wire terminal connections for assembling the control handle if replacing the handle’s electrical cable 77
3 Remove the locknuts to disconnect the studded rod ends on the control rods from the control handle assemblies 77
4 Remove capscrews, washers and locknuts on the elastomeric rod ends attaching the control handle assemblies to the crossmember Remove the handle assembly 77
NOTE: 78
Control Handle Removal and Installation – T-Bar Controls 78
WARNING 78
1 Remove the control console per the procedure in the Mainframe chapter 78
2 Disconnect the electrical connector in both control handles at the end of the wire Note the wire terminal connections for assembling the control handle if replacing the handle’s electrical cable 78
3 Remove the locknuts to disconnect the studded rod ends on the control rods from the control handle assemblies 78
4 Remove capscrews, washers and locknuts on the elastomeric rod ends attaching the control handle assemblies to the crossmember Remove the handle assembly 79
NOTE: 79
T-Bar Control Handle Assembly 79
NOTE: 79
1 Slide the T-Bar boot up the T-Bar control handle 79
2 Attach elastomeric rod ends to sides of pivot with capscrews, washers and locknuts 79
Elastomeric Rod Ends 79
3 Press or drive two bronze bearings into holes on pivot Use a bearing driver, if available 79
4 Thread the four (left side) or eight (right side) electrical wire terminals in the control grip through a hole at the top of the control handle 80
5 Place a small rubber cap over the ends of the electrical wires and feed it into a hole leading inside the control handle 80
6 Install the left control grip at the top of the control handle aligning the hole in the grip with the hole in the handle 80
NOTE: 80
7 Insert roll pin through the aligned holes to secure the left handle grip to the control handle 80
8 Place top half of pivot and two washers on control handle, then slide handle through pivot 80
9 Place T-Bar stop between washers: 80
Capscrew 81
10 Insert the four and eight wire terminals into their corresponding electrical connector housings 81
Four-pin Connector 81
Eight-pin Connector 81
11 Press an orange wedge into the other ends of the connector housings 81
Dual Joystick Control Handle Assembly 82
1 Using a rubber mallet, hammer two bronze bearings into the lower portion of the joystick tower 82
2 Insert the tilt console pin into the bronze bearings and secure with external retaining rings 82
3 RT165/1650RT Models: Attach the ratchet handle to the joystick tower with a flat washer and carriage bolt 82
4 Screw six adapters into the bottom of the joystick There are four smaller of one size and two larger of another size Consult the illustrations in this manual or the parts manual for correct installation of these adapters 82
5 Screw down and attach the control grip to the top of the joystick 82
6 Route the electrical wire in the control grip through a slot in the joystick 83
7 Slip the entire assembly into the joystick stand 83
8 Bolt the joystick onto the joystick stand 83
9 View of joystick secured onto the joystick stand 83
10 Connect the tower cover to the joystick stand with four machine screw 83
11 Pull the boot down over the control grip and top of the joystick stand 83
12 View of correctly orientated control handles 83
Hand/Foot Control Handle Assembly 84
1 Slide the two boots and foam pad onto the control handle 84
2 Attach elastomeric rod ends to sides of pivot with capscrews, washers and locknuts 84
3 Using Loctite 242 on the threads of each control grip, screw the grips into the top of each control handle weldment Tighten the nut on the grip to secure BE SURE the grips are situated for easy controllability by the operator 84
4 Thread the four (left side) or eight (right side) electrical wire terminals in the control grip through a hole at the top of the control handle 84
5 Insert the four and eight wire terminals into their corresponding electrical connector housings 85
Four-pin Connector 85
Eight-pin Connector 85
6 Press an orange wedge into the other ends of the connector housings 85
Pivot Tube Removal and Installation, Disassembly and Assembly – T-Bar and Hand/ Foot Controls 85
WARNING 85
1 Remove the crossmember per the procedure in the Mainframe chapter 85
NOTE: 85
2 Disassemble the pivot tube assembly on a workbench to replace parts as needed 85
3 Remove locknuts securing rod end studs on the pivot tube arms and remove studs/control rods from the arms 85
4 Remove hex nut on each centering device 86
5 Remove capscrews securing the pivot tube control mount to the crossmember 86
6 Slip both pivot brackets off the ends of the control pivot shaft and remove the pivot assembly 86
7 A bronze bearing is pressed into both pivot brackets, remove them from their brackets 86
8 Remove two roll pins in the pivots and slide all pivots and washers off the shaft Bronze bearings are pressed onto the control pivot shaft, remove them from the shaft 86
NOTE: 86
NOTE: 86
Control Handle Position Adjustment – T- Bar and Hand/Foot Controls 87
WARNING 87
1 Left Control Handle: Adjust two control rod lengths connected at the pivot assembly, so that the bracket on the pivot assembly is oriented 90° to the chassis 87
2 Left Control Handle Vertical Orientation: Adjust two control rod lengths connect at the pivot assembly to realize a 8° forward tilt to the handle 87
3 Right Control Handle Vertical Orientation: Adjust lift control rod length attached to bottom of pivot assembly to realize a 8° forward tilt to the handle 87
4 Right Control Handle Orientation: Adjust the tilt control rod length until it is oriented 90° to the chassis BE SURE the adjustment allows for full activation of the control valve in both directions of handle operation 87
5 Reference the illustration on the previous page for additional clarification 87
Control Handle Tracking Adjustment 87
WARNING 87
1 Decide which side needs to be adjusted If the loader turns right while going FORWARD, the left side speed must be reduced, and vice versa DO NOT attempt to increase speed of either side, because it may damage the hydrostatic pump 87
FORWARD Adjusters 87
NOTE 87
2 If the loader turns right in FORWARD position, use an allen wrench to hold the stud in place while loosening the locknut With the allen wrench in clockwise motion, tighten 1/4 turn Retighten the locknut 88
3 If the loader turns right in REVERSE position, use the adjustment points opposite the FORWARD position adjustment points in step 2 88
4 If the loader turns left in FORWARD position, use an allen wrench to hold the stud in place while loosening the locknut With the allen wrench in clockwise motion, tighten 1/4 turn Retighten the locknut 88
5 If loader turns left in REVERSE position, use the adjustment points opposite the FORWARD position adjustment points in step 4 88
6 Lower and secure ROPS/FOPS Start the loader Test loader tracking; repeat the adjustment as needed 88
WARNING 88
1 Decide which capscrew to adjust If the loader turns right, the left side speed must be reduced and vice versa DO NOT attempt to increase the speed of either side, it may cause the control arm assemblies to overtravel, resulting in damage to the 88
2 If the loader is turning right, loosen the locknuts on the left, top and bottom capscrews In a counterclockwise motion, unscrew the capscrew 1/2 turn and retighten the nuts 88
3 If the loader is turning left, loosen the locknuts on the right, top and bottom capscrews In a counterclockwise motion, unscrew the capscrews 1/2 turn and retighten the nuts 88
4 Lower and secure the ROPS/FOPS Start the loader Test loader tracking, repeat adjustments as needed After correct adjustment, reinstall the control consoles 88
Neutral Centering Test and Adjustment 89
WARNING 89
1 Mark and disconnect the pilot lines going into the top of the pump for the section being tested 89
2 Plug the end of the hoses Do not cap the fittings on the transmission 89
3 Disconnect the drive hoses from the section being tested 89
4 Plug the drive hoses and cap the fittings on the transmission 89
5 Connect X1 and X2 ports together by means of 1/4” internal diameter hose or tubing 89
X1 89
6 Install 8702 psi (600 bar) pressure gauges in MA and MB of the section being tested 89
7 Block ports A and B ports blocked (or apply the parking brake) 89
8 Start the machine observing safety practices 89
9 Loosen the jam nuts on the neutral adjustment screws 89
10 Turn the mechanical centering adjusting screw until 1000 psi (70 bar) is read on the pressure ports 89
11 Turn the screw back, splitting the distance between the previous two positions 89
Note: 89
12 Tighten the jam nut on the adjustment screws when equal pressure is measured on both gauges 89
13 Stop the pump drive 89
14 Remove the hose connecting ports X1 and X2 Reinstall plugs where MA and MB were checked 89
15 Adjust NEUTRAL in the other section, if necessary 89
WARNING 90
1 Remove one hex nut on each rod end attached to the hydrostatic control arms 90
NOTE: 90
2 Twist the rod ends on the control rods until they slip over the capscrew and spacer without the control arms or centering devices moving Tighten the rod ends to the control arms and then the jam hex nuts to the rod ends 90
3 Test the operation of the control handle, push the control handle forward and backward and allow the centering devices to return the control handle to the NEUTRAL position 90
IMPORTANT 90
Lift/Tilt Control Removal and Installation 91
WARNING 91
1 Remove the floor plate and kickplate cover per the procedure in the Mainframe chapter 91
2 Between the foot pedals, remove three capscrews securing the clean-out cover (or doghouse cover) and lift it out of the loader 91
3 Disconnect the lift and tilt control cables attached to the foot pedals and loosen the jam nuts on the foot pedal mount weldment 91
4 Disconnect the lift and tilt control cables at the main control valve 91
5 Loosen the jam nuts on the control cables just in front of the control valve and release them from their mounting bracket 91
6 From the front of the loader, carefully pull both cables out of the loader 91
7 To reassemble, refer to the exploded view near the front of this chapter as a guide 91
WARNING 92
1 Disconnect hydraulic pressure hoses from the control valve, two in the rear and three in front 92
RT165/1650RT Models 92
RT135/1350RT Models 92
RT165/1650RT Models 92
RT135/1350RT Models 92
IMPORTANT: 92
2 Disconnect two hydraulic hoses from the solenoid attached at the crossmember 92
RT165/1650RT Models 92
RT135/1350RT Models 93
3 Disconnect two hydraulics hoses from another solenoid located beneath the crossmember 93
RT165/1650RT Models 93
RT135/1350RT Models 93
4 Remove the hydraulic hoses from the loader 93
5 To reassemble, refer to the exploded view near the front of this chapter as a guide 93
WARNING 93
1 Remove the control console per the procedure in the Mainframe chapter 93
2 Disconnect the clevis assembly on the lift control rod from the main control valve 93
3 Disconnect the clevis assembly on the tilt control rod from the main control valve 93
4 Disconnect the electrical connector at the bottom of each control handle 93
5 Remove two capscrews, washers and locknuts securing the T-Bar pivot to two elastomeric rod ends at the front of the crossmember 94
6 Pull the control handle assembly forward and out 94
Lift/Tilt Control Adjustment – T-Bar and Hand/Foot Controls 94
WARNING 94
1 The lengths of the lift and tilt control rods can be adjusted to obtain proper position of the Hand/Foot and T-Bar control models Refer to the “Control Handle Position Adjustment” procedure in this chapter 94
2 The “Self-Leveling Valve Adjustment” procedure in the Hydraulic System chapter is also related to correct operation of the lift and tilt controls Refer to this procedure as needed 94
Electrical Foot Throttle Removal and Installation – (Option) 94
WARNING 94
1 Remove the floor plate and kickplate cover per the procedure in the Mainframe chapter 94
2 Unplug the electrical connector on the electric foot throttle 96
3 Remove four nuts and bolts securing the foot throttle assembly to the chassis floor plate 96
4 Remove the entire electric foot throttle assembly from the track loader 96
HYDROSTATIC SYSTEM 97
WARNING 97
WARNING 97
Charge Pressure Test and Adjustment 105
NOTE: 105
WARNING 105
1 Locate the test port near the control valve on Models RT165/1650RT 105
Charge Pressure Test Port 105
Charge Pressure Test Port 105
High Pressure Relief Valves – T-Bar & H/F 105
Charge Relief Valve – DJS 105
2 Remove the metal cap from the test port (ISO 15171-2, coupling with M16x2 end for connections under pressure ) 105
3 Install a pressure gauge on the charge pressure test port 105
4 Restart the engine and allow it to run until the hydraulic oil is at operating temperature, around 140° F (60° C) and check the pressure reading on the gauge The gauge should read as follows: 105
5 If the pressure reading on the gauge is either lower or higher than specified, refer to the manufacturer’s service manual for the hydrostatic pump and the charge pressure adjustment procedure that follows 105
6 When finished, reinstall the metal cap on the test port 105
Hydrostatic Pump Relief Valves 106
Dual Joystick Pump 106
T-Bar & H/F Pump 106
Hydrostatic Pump Removal and Installation 106
WARNING 106
1 Drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter 106
2 Remove the control console, floor plate and crossmember per their procedures in the Mainframe chapter 106
3 Remove the auxiliary pump per the procedures in the Hydraulic System chapter 106
IMPORTANT: 106
4 Pilot Controls: Label and disconnect all the hydraulic hoses and tubes from their fittings connected to the hydrostatic pump 107
5 Servo Controls: Disconnect the control rods attached to pump control arms at the top of the hydrostatic pump 107
6 Position a hoist above the hydrostatic pump Attach lifting straps around the pump and raise the hoist to remove slack from the strap/hook The hoist should now support the weight of the pump 107
7 Remove the two capscrews (55 lbf-ft) (74,6 N•m) and washers securing the hydrostatic pump to the flywheel housing Use Loctite™ 242 or equivalent to reinstall 107
8 Shift the hydrostatic pump forward to disengage the splined shaft drive of the pump 107
9 Lift and maneuver the hydrostatic pump out of the track loader 107
10 If necessary, remove the splined coupler from the pump Remove two socket-head screws (25 lbf-ft) (34 N•m) on the coupler and slip it off the pump shaft Before doing so, measure the distance (0 39 – 0 42”) (9,9 – 10,6 mm) between the face of 107
Measure This Distance 107
Hydrostatic Pump Drive Coupling Removal and Installation 108
WARNING 108
1 Remove the hydrostatic pump per the procedure in this chapter 108
2 Remove the socket-head capscrews (39 lbf-ft) (52,8 N•m) securing the flywheel housing to the engine Use Loctite™ 242 or equivalent to reinstall 108
3 Remove the capscrews (39 lbf-ft) (52,8 N•m) attaching the flexible coupling plate to the engine Use Loctite™ 242 or equivalent to reinstall 108
4 Do not apply any lubrication or grease to the flexible coupling plate when reinstalling The leading edge of the coupler hub is to be positioned 0 39”- 0 42” (9,9 mm – 10,6 mm) from the surface of the hydrostatic pump Torque the set screws on 108
Table 1: Hydrostatic Drive System Troubleshooting 109
Troubleshooting Guide 109
Pressure Check, Test and Adjustment 145
RT165/1650RT shown; others similar 145
1 At the Hydraulics Couplers: Climb into the operator’s seat, lower the restraint bar and start the engine 145
2 Activate the standard control function of the standard auxiliary, or high-flow auxiliary if checking that 145
3 Slowly increase the engine speed to high idle 145
4 Have assistant observe the pressure reading on the gauge The pressure reading on the loader should be: 145
5 If the pressure reading is NOT between the specified pressures, adjust the pressure as follows 145
WARNING 145
NOTE: 145
6 Remove the cap(s) on the relief valve adjuster screw(s) The high-flow auxiliary relief valve is located at the top rear of the control valve The standard auxiliary relief is beneath the high-flow relief at the rear of the control valve 145
High-Flow Auxiliary Relief Valve 145
Standard Auxiliary Relief Valve 146
Standard Auxiliary Relief Valve 146
7 With an assistant’s help, set the engine to high idle, actuate the auxiliary function and monitor the pressure on the gauge 146
8 With a flat-edge screwdriver, turn the adjuster screw IN to increase pressure or OUT to reduce pressure 146
Adjuster Screw 146
9 After the pressure is within the correct PSI (bar) range, replace the cap over the adjuster screw 146
10 If, after adjustment, there is NO CHANGE in the pressure reading, this indicates either a defective auxiliary pump or relief valve cartridge (on the control valve) To determine which is the cause, first replace the relief valve cartridge If the 146
Tilt Cylinder Test 146
NOTE: 146
WARNING 146
IMPORTANT: 146
1 Checking one tilt cylinder at a time, remove the upper hydraulic hose from the cylinder being tested, and cap or plug the hose Caps/plugs MUST BE able to withstand full hydraulic pressure 146
2 Install an extra hose to the upper cylinder port and place the other end of this hose into an empty bucket 147
3 Climb back into the operator’s seat, lower the restraint bar, and start the engine Have an assistant watch the hose in the bucket 147
4 Slowly actuate the roll back (curl) function of the hitch If oil streams into the bucket, the cylinder seals are malfunctioning Replace the cylinder seals 147
5 After the tilt cylinder has been tested, be sure to reconnect the tilt cylinder hydraulic hose removed in step 1 147
6 Repeat steps 1 – 5 for the other side 147
Tilt Circuit Spool Leakage Test 147
WARNING 147
1 Required Equipment: Pressure Gauge (0-5000 psi) (345 bar), infrared thermometer, two people, tape measure or caliper, stop watch 147
2 Install the pressure gauge into the hydraulic circuit of the rod end of the tilt cylinder The gauge can be installed anywhere between the cylinder and the control valve 147
3 Idle the machine until the hydraulic oil is stabilized at 120° F (49° C) The oil temperature can be determined by using the infrared thermometer The temperature area of the cooler is shown in red in the following photograph Once the temperatu 147
4 Attach a dirt/construction bucket to the machine Position the bucket so that approximately 0 5″ (12,7 mm) of the rod is exposed 147
5 Add weight to the bucket until the pressure gauge reads 1400-1500 psi (96,5 – 103 bar) 147
6 Roll back the bucket fully Find a position that can be easily measured between the barrel of the cylinder and the rod Record this dimension 147
WARNING 148
7 Shut the machine off Have the operator turn the key to the ON position and remain in the seat with the restraint bar down (This is done to ensure the additional hydraulic locks remain open for the test period) 148
8 Begin recording time on the stop watch 148
9 After a period of ten minutes, record the amount that the cylinder had moved 148
10 Compare to the allowable movement of 1 07” (27,2 mm) in a 10 minute period This is the highest allowable leakage value per the valve manufacturers specifications 148
Self-Leveling Valve Test 148
WARNING 148
1 With the engine OFF and the ROPS raised and locked, remove the plastic cap and loosen the jam nut on the self-leveling valve adjuster screw 148
Self-Leveling Valve Adjuster Screw 148
Self-Leveling Valve Adjuster Screw 148
NOTE: 148
2 With an allen wrench, turn the adjuster screw in (clockwise) until it bottoms out The self-leveling valve is now disabled and will not affect the tilt operations 148
3 Perform steps 3-5 in the “Tilt Cylinder Test” procedure If the bucket no longer drifts, the self-leveling valve is defective If the bucket continues to drift, the control valve is defective and in need of repair or replacement 148
4 Refer to the “Self-Leveling Valve Adjustment” procedure in this chapter for correct adjustment of the self-leveling valve 148
Lift Cylinder Test 149
NOTE: 149
WARNING 149
1 Remove the clamp securing the hydraulic tubes to the lift cylinder on the side being tested 149
IMPORTANT: 149
2 Disconnect the hydraulic tube from the rod end port of the lift cylinder to be tested 149
3 Install a plug on the hydraulic tube Attach a hose to the rod end port of the cylinder and run the other end of the hose into a suitable container 149
4 Climb into the operator’s seat, lower the restraint bar and start the engine 149
5 Hold the lift control in the RAISE position to extend both cylinders (a small amount of oil will exit the hose initially) If the seals in the cylinder are defective and leaking, oil will flow out of the rod end port 149
6 Slowly lower the lift arm until the support device contacts the lift cylinder Shut off the engine and relieve hydraulic pressure with the lift control 149
7 Reconnect the tube to the cylinder, then reattach the clamp around the hydraulic tube and cylinder 149
8 The other cylinder can be checked the same way 149
NOTE: 149
9 Relieve hydraulic pressure Disconnect the ride control tubes to port A & B of the ride control manifold Cap the fittings on the hydraulic tubes 149
RT165/1650RT shown; others similar 149
10 Raise the lift arm, engaging the lift arm support device, and check for drifting 149
11 With an operator in the seat, the keyswitch set to the ON position and the restraint bar lowered, check to see if drifting has subsided, if so, then the solenoid valve nearest port A of the ride control manifold should be replaced 149
12 If drifting remains after disconnecting the ride control manifold, then the control valve is at fault and should be replaced 149
Lift Circuit Spool Leakage Test 150
WARNING 150
1 Required Equipment: Pressure Gauge (0-5000 psi) (345 bar), infrared thermometer, two people, Tape measure or caliper, stop watch 150
2 Install the pressure gauge into the hydraulic circuit of the base end of the lift cylinder The gauge can be installed anywhere between the cylinder and the control valve 150
3 Idle the machine until the hydraulic oil is stabilized at 120° F (49° C) The oil temperature can be determined by using the infrared thermometer The temperature area of the cooler is shown below Once the temperature of the cooler has not vari 150
4 Attach a bucket to the machine Position the bucket so that 5 00″-6 00” (127 – 152 mm) of rod is exposed 150
5 Add weight to the bucket until the pressure gauge reads 1400-1500 psi (96,5 – 103 bar) 150
6 Roll back the bucket fully and raise the lift arm so that 5 00″-6 00” (127 – 152 mm) of the rod is exposed Find a position that can be easily measured between the barrel of the cylinder and the rod Record this dimension 150
WARNING 150
7 Shut the machine off Have the operator turn the key to the ON position and remain in the seat with the restraint bar down (This is done to ensure the additional hydraulic locks remain open for the test period) 150
8 Begin recording time on the stop watch 150
9 After a period of ten minutes, record the amount that the cylinder had moved 150
10 Compare to the allowable movement of 0 75” (19 mm) in a 10 minute period This is the highest allowable leakage value per the valve manufacturers specifications 150
Solenoid Valve Test – Lift Arm Pilot Supply, Joystick Drive Supply, Power-A-Tach, Brake/Two-Speed, Safety Locks and Ride Control 150
1 Climb into the operator’s seat, lower the restraint bar and start the engine 151
2 BE SURE the parking brake switch on the instrument panel is in the OFF position 151
3 Raise the restraint bar Operate the drive controls (one at a time) to see if the tracks will move If the skid loader moves forward or backward, the system is malfunctioning Possible causes for the malfunction include, but are not limited to: 151
Brake/Two-Speed 151
Joystick Drive Supply 151
Joystick Drive Supply 151
Lift Arm Pilot Supply 151
Lift Lock 152
Power-A-Tach 152
Tensioner 152
Tensioner 152
4 If any solenoid in the tests appears to be malfunctioning, test the solenoid coil(s) as follows: 152
WARNING 152
5 For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter 152
1 Climb into the operator’s seat, lower the restraint bar and start the engine 152
1 Clear the area of bystanders and raise the lift arm half way up 152
2 Actuate the ride control button on the right control handle If the solenoid is functioning properly, there should be a slight (minimal) drop in the lift arm height and a light in the instrument panel should illuminate 153
Hydraglide™ Solenoid 153
3 Lower the lift arm 153
4 If the Hydraglide™ solenoid valve in the test appears to be malfunctioning, test the solenoid coils as follows: 153
WARNING 153
5 Lower the restraint bar, turn the keyswitch to ON (DO NOT start the engine) Compress the operator’s seat and hold to temporarily bypass the interlock safety system 153
6 Actuate the Hydraglide™ button to see if the coil magnetizes 153
7 Have an assistant do the metal ruler test: 153
8 For service procedures, refer to “Solenoid Valve Removal and Installation/Disassembly and Reassembly” procedure in this chapter and the Electrical System chapter Troubleshooting Guide Also look at the module test procedures and LED truth tabl 153
Hydraulic Oil Filter Element Replacement 156
NOTE: 156
WARNING 156
1 Open the engine access cover and lock open the rear grille 156
2 Clean any dirt/debris off the surface of the filter housing 156
3 Remove the hydraulic reservoir drain plug from the bottom of the reservoir in the right riser and drain the oil (into a suitable container) to a level below the point where the filter attaches to the reservoir Use an allen wrench to remove the plug 156
Hydraulic Oil Drain 156
4 Reinstall the drain plug 156
5 Using a filter wrench, turn the filter element counterclockwise to remove it from the filter head 156
6 Install the new filter element Before installation, apply a light coat of oil to the gasket and then install it on the filter head 156
7 Hand-tighten the element until the gasket contacts the filter head Turn the element another 3/4 turn to seat the gasket 156
8 Refill the hydraulic reservoir Refer to the Lubrication chapter in this manual for the hydraulic fluid requirements and specifications 156
WARNING 156
WARNING 156
9 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 156
Tilt Cylinder Removal and Installation 157
NOTE: 157
1 Remove the bucket or attachment 157
2 With the engine running, lower the lift arm until it is in contact (or near contact) with the lift arm stops (on front of chassis) 157
WARNING 157
3 Disconnect the upper and lower tilt cylinder hoses from the tubes on the crossmember BE SURE to plug the hoses and cap the fittings to prevent fluid loss and contamination of the hydraulic system 157
4 While supporting the weight of the tilt cylinder, remove the capscrew and locknut securing the lower tilt cylinder pivot pin Then drive the pivot pin out to release the lower end of the tilt cylinder 157
5 Loosen the capscrew on the end of the upper tilt cylinder pin by two to three counterclockwise turns Strike the bolt head to drive the pin into the lift arm and break the pin free of the taper Remove the capscrew and flat washer Remove the uppe 157
6 Remove upper and lower hoses from the cylinder 157
WARNING 157
1 Connect the upper and lower hoses to the tilt cylinder 157
2 Install the base end of the tilt cylinder in position on the lift arm and insert the pivot pin Use Loctite® 242 (or equivalent) on the capscrew before reinstalling and torque to 80 ft -lbs (108 N•m) 158
3 Position the rod end of the tilt cylinder and insert the pivot pin through the cylinder and attachment mount Secure the pivot pin with a capscrew and/or washer and locknut 158
4 Remove plugs/caps and attach the upper and lower tilt cylinder hoses to the cylinder, and then reconnect hoses to the tubes on top of the crossmember 158
NOTE: 158
WARNING 158
WARNING 158
5 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 158
Lift Cylinder Removal and Installation 158
1 Remove the bucket or attachment 158
WARNING 158
2 Raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized and attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent to the hitch 158
3 On models RT165/1650RT, remove the clamp that secures the hydraulic tube to the lift cylinder 158
RT165/1650RT shown; others similar 158
NOTE: 158
4 Disconnect the two hydraulic hoses at the base end of the lift cylinder BE SURE to install plugs/caps in the hoses/tubes to prevent fluid loss and contamination of the hydraulic system 158
CAUTION 159
5 Remove the capscrew and washer securing the top lift cylinder pivot pin Drive the pivot pin out to release the rod end of the lift cylinder 159
Pivot Pin 159
6 While supporting the weight of the lift cylinder, remove the capscrew and locknut securing the rear lift cylinder pivot pin Drive the pivot pin out the hole on the outside of the chassis Remove the lift cylinder from the chassis 159
1 Attach a suitable hoist of adequate capacity and a positive locking mechanism able to support the lift arm or equivalent to the hitch and raise the lift arm to a position where access to the tubes and hoses on the lift cylinder is maximized 159
2 Install the lift cylinder on the chassis so the rod end is facing forward and the hydraulic tube ports on the cylinder are facing inward 159
3 Apply anti-seize grease on pin ends and insert the rear and front pivot pins through the cylinder pivots and secure them with capscrews and locknuts 159
4 Remove the plugs/caps and connect the two hydraulic hoses to the lift cylinder according to the markings made at removal If no markings were made or new parts were installed, refer to the Hydraulic System chapter exploded views 159
NOTE: 159
WARNING 159
WARNING 159
5 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 159
6 Remove the hoist 159
Auxiliary Pump Removal and Installation 160
WARNING 160
1 If necessary, drain the hydraulic oil tank per the procedure in the Lubrication chapter 160
2 If necessary, remove control consoles and floor cover per their procedures in the Mainframe chapter 160
3 If necessary, remove the crossmember per the procedure in the Mainframe chapter 160
4 Disconnect all hydraulic hoses from their fitting(s) or hose clamp on the auxiliary pump and remove the hose(s) 160
RT165/1650RT shown; others similar 160
IMPORTANT: 160
5 Remove two capscrews and washers attaching the auxiliary pump to the hydrostatic pump 160
6 Pull the auxiliary pump forward and out of the hydrostatic pump BE CAREFUL not to lose the o- ring 160
1 Install the o-ring on the mating surface of the auxiliary pump 160
2 Attach the auxiliary pump to the hydrostatic pump (BE SURE the auxiliary pump shaft engages the splined coupler) Install two capscrews and lock washers to secure the auxiliary pump to the hydrostatic pump 160
3 Remove the caps/plugs and connect the hydraulic hoses to the auxiliary pump 160
4 If performed at removal, reinstall the crossmember, floor plate and control consoles per their procedures in the Mainframe chapter 160
5 If performed at removal, reinstall the hydraulic reservoir drain plug 160
6 If performed at removal, replace the hydraulic oil drained out of the reservoir in step 1 160
NOTE: 160
WARNING 161
WARNING 161
7 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 161
Self-Leveling Valve (Optional) Removal and Installation 161
WARNING 161
NOTE: 161
NOTE: 161
1 Disconnect the electrical connector from the self- leveling valve 161
RT165/1650RT shown; others similar 161
2 Disconnect all the hydraulic tubes from their hydraulic fittings on the self-leveling valve 162
RT165/1650RT shown; others similar 162
3 Remove the two carriage bolts, spacers and locknuts securing the self-leveling valve to the chassis 162
4 Remove the self-leveling valve 162
NOTE: 162
WARNING 162
WARNING 162
5 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 162
Self-Leveling Valve Adjustment 163
1 Raise and lower the lift arm several times to ensure there is no air in the hydraulic system 163
2 Lower the lift arm completely, then fully retract the tilt cylinders (roll back) 163
3 Raise the lift arm to its maximum height; then lower it to the ground 163
4 Measure how far the tilt cylinder rod extends from the tilt cylinder The distance should be between 8- 1/4 and 8-1/2” (210-216 mm) If measurement is outside this range, the self-leveling valve should be adjusted according to steps 5 – 7 of thi 163
WARNING 163
5 The self-leveling valve can be accessed from the left side of the chassis 163
6 Remove a plastic cap at the front of the valve and loosen the adjuster screw locknut on the self-leveling valve 163
7 Insert an allen wrench into the adjuster screw on the self-leveling valve and adjust the valve Turn the screw IN (clockwise) to shorten the cylinder extension Turn the screw OUT (counterclockwise) to lengthen the cylinder extension 163
8 To check for proper operation, lower the ROPS, climb into the operator’s seat, lower the restraint bar and start the engine Disengage the lift arm support device and secure it to the lift arm 163
9 Repeat steps 2 through 4 above to check for proper operation of the self-leveling valve If further adjustment is needed, perform the safety procedures again and repeat steps 5 through 7 163
10 After adjustment is complete, tighten the adjuster screw locknut 163
Brake/Two-Speed, Lift Arm Pilot Supply and Safety Lock Solenoid Valves – Removal and Installation 164
WARNING 164
IMPORTANT: 164
NOTE: 164
1 Lift and Tilt Safety Lock Valves Removal: Disconnect two electrical connectors on the solenoid coils Remove two hydraulic tubes from their fittings Remove two locknuts securing the valve to the valve mounting plate Disconnect two forward hydrau 164
Lift Lock 164
2 Lift Safety Lock Valve Removal: Disconnect two electrical connectors on the solenoid coils Remove two hydraulic tubes from their fittings Remove the valve 164
Lift Arm Pilot Supply 164
3 Brake/Two-Speed Valve Removal: Disconnect two electrical connectors on the solenoid coils Remove four hydraulic hoses on the lock valve Remove two locknuts securing the valve to the chassis Remove the valve 164
Brake/Two-Speed 164
NOTE: 165
WARNING 165
WARNING 165
4 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 165
Joystick Drive Supply, Power-A-Tach and Hydraglide™ Ride Control Solenoid Valves – Removal and Installation 165
WARNING 165
IMPORTANT: 165
NOTE: 165
1 Identify and mark connectors, then disconnect the electrical connectors on the solenoid coil Identify and mark tubes and hoses, then disconnect the hydraulic tubes or hoses from their fittings on the solenoid valve Remove the capscrews and lockn 166
Joystick Drive Supply 166
Hydraglide™ Solenoid 166
Power-A-Tach 166
2 Remove the solenoid manifold from the track loader 166
NOTE: 166
WARNING 166
WARNING 166
3 ALWAYS check for hydraulic fluid leaks after reassembling components of the hydraulic system 166
Lift/Tilt, Joystick Drive Supply, Brake/Two- Speed, All-Tach/Fan and Hydraglide™ Ride Control Solenoid Valves – Disassembly and Assembly 167
1 Remove the nut that secures the coil to the cartridge 167
2 Remove the coil from the cartridge 167
3 Unscrew cartridge from the valve body 167
4 Install seal kit (or other new parts) Assemble solenoid valve in reverse order of disassembly 167
O-Ring 167
IMPORTANT 167
Control Valve Removal and Installation 168
WARNING 168
1 If necessary, (see following NOTE), drain oil from hydraulic reservoir For this procedure refer to “Hydraulic Reservoir” in the Lubrication chapter 168
2 T-Bar Models Only: Disconnect the lift and tilt rods on two spools See “Lift/Tilt Control Removal and Installation” on page 80 in the Controls chapter 168
3 High-Flow Only: Disconnect four electrical connectors on the control valve, two at the front and two more at the rear of the valve 168
4 Standard Flow Only: Disconnect two electrical connectors on the control valve, one at the front and one more at the rear of the valve 168
NOTE: 168
NOTE: 168
NOTE: 168
NOTE: 168
DJS High-Flow Valve shown for reference 168
5 Port 1: Disconnect the hydraulic tube at its fitting on the control valve 168
6 Port 3: Disconnect the hydraulic hose/tube at its fitting on the control valve 168
7 Port 2, 4 and 5: Disconnect the hydraulic hose/ tubes from their fittings on the control valve 168
8 Ports 6, 7, 8, 11, 12 and 13: Disconnect the hydraulic tubes from their fittings on the control valve 168
9 Ports 9 and 10: Disconnect the auxiliary pump hydraulic hoses from their fittings on the control valve 168
10 Port 14: Disconnect the hydraulic hose/tube from its fitting on the control valve 168
11 Ports 15, 16, 17 and 18: Disconnect the hydraulic hoses from their straight fitting on the control valve 171
12 Inside the chassis, remove four capscrews securing the control valve to its welded-on mounting bracket on top of the chaincase 171
13 Lift out the control valve Removal may require loosening the opposite ends of some of the disconnected tubes 171
DJS High-Flow Valve shown for reference 171
1 Secure the control valve to its welded-on mounting bracket on top of the chaincase with four capscrews If the fittings are not already installed in the valve, install them at this time 171
2 Ports 15, 16, 17 and 18: Connect the hydraulic hoses to their straight fittings on the control valve 171
3 Port 14: Connect the hydraulic hose/tube to its fitting on the control valve 171
4 Ports 9 and 10: Connect the auxiliary pump hydraulic hoses to their fittings on the control valve 171
5 Ports 6, 7, 8, 11, 12 and 13: Connect the hydraulic tubes to their fittings on the control valve 171
6 Port 2, 4 and 5: Connect the hydraulic hose/tubes to their fittings on the control valve 171
7 Port 3: Connect the hydraulic hose/tube at its fitting on the control valve 171
8 Port 1: Connect the hydraulic tube at its fitting on the control valve 171
9 Install hydraulic reservoir drain plug and refill with correct type of hydraulic oil Refer to Lubrication chapter for hydraulic oil specifications 171
10 ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system 171
WARNING 171
WARNING 171
Control Valve Disassembly and Assembly 172
NOTE: 172
1 Remove the main control valve per the procedure in this chapter and place valve on a flat surface that can retain or collect any hydraulic oil spill 172
2 To access the spools, use an Allen wrench to loosen the two or four socket capscrews securing all the spool caps 172
Two Screw Spool Cap 172
Four Screw Spool Cap 172
3 Pull spool cap off the spool and retain the o-rings 172
Two Screw Spool Cap 172
Four Screw Spool Cap 172
4 Grab the spring assembly on the end of the spool and pull the spool out of the control valve Identify and mark the spools and reinstall them (later) in the same location 172
Spool 172
5 Repeat steps 2-4 for all spools that need to be removed from the control valve 172
6 To remove any of the port relief valves or the inlet relief valve from the control valve, use a wrench to loosen the valve from the control valve Check the condition of the o-rings and clean off any debris 172
Port Relief Valve 173
O-Ring 173
Control Valve Solenoid Removal and Installation 173
NOTE: 173
WARNING 173
1 Unplug the electrical connector on the valve solenoid to be serviced 173
2 Using an Allen wrench, remove two screws securing the solenoid to the valve 173
3 Check the condition of the cartridge and o-rings and clean off any debris Check the solenoid output, if necessary (see the Electrical System chapter) 173
Inlet Relief Valve, Port Relief Valve and High-Flow Relief Valve Removal and Installation 174
NOTE: 174
WARNING 174
1 With a wrench, loosen and remove the inlet relief valve or drain orifice from the main control valve 174
Inlet Relief Valve 174
Port Relief Valve 174
High-Flow Relief Valve 174
2 Check condition of o-rings and clean off any debris 174
Hydraglide™ Ride Control Accumulator Removal and Installation 175
WARNING 175
1 Disconnect three electrical connectors on the manifold 175
2 Remove two hydraulic tubes and one hydraulic hose from their fittings on the manifold 175
IMPORTANT: 175
3 Remove two capscrews and locknuts securing the accumulator and manifold to the chassis Remove the accumulator 175
NOTE: 175
4 ALWAYS check for hydraulic fluid leaks after reassembling any component of the hydraulic system 175
HYDRAULIC SYSTEM 117
IMPORTANT 117
WARNING 117
WARNING 117
Table 1: Hydraulic System Troubleshooting 117
CHAPTER NOTES 176
ELECTRICAL SYSTEM 177
Description of Operation – Operator Safety Interlock 177
1 When the operator is in the seat, the restraint bar is down, and the keyswitch is turned to the “ON” position, the following indicator lamps will light: 177
NOTE: 177
2 The keyswitch can then be turned to the “START” position 177
3 The pilot supply solenoid valves should be energized when the operator is on the seat, the restraint bar is down, and the keyswitch is turned to the ON position 177
NOTE: 177
Right Instrument Panel – Control Keypad Indicators 177
Table 1: Control Keypad Indicators 177
Figure 1 – Control Keypad Indicators 177
Right Instrument Panel – Control Keypad Buttons 179
Figure 2 – Control Keypad Buttons 179
Table 2: Control Panel Buttons 179
Right Instrument Panel – Information Center Electronic Display 180
Figure 3 – Information Center Electronic Display 180
Information Center Electronic Display Symbols 181
Table 3: Symbols Descriptions 181
Information Center Electronic Display Screens 182
Table 4: Status, Maintenance and Error Code Screens 182
A Fuel level 182
B Engine coolant temperature 182
C Accumulated operation time 182
D Amber error condition warning Causes DM1/DM2 errors screen(s) to display 182
E Red critical error warning Causes DM1/DM2 errors screen(s) to display 182
F Engine coolant temperature amber warning region Indicates elevated coolant temperature 182
G Engine coolant temperature red stop warning region Indicates serious coolant overheating condition 182
H Fuel level amber warning region Indicates low fuel level 182
I Fuel level red stop region Indicates almost empty fuel tank 182
Left Instrument Panel – Accessory Keypad Indicators/Buttons 185
Table 5: Accessory Keypad Buttons 185
Figure 4 – Accessory Keypad Indicators/Buttons 185
Left Instrument Panel – Optional Lights/ Lockout Keypad Indicators/Buttons 186
Table 6: Optional Road Lights/Lockout Keypad Buttons 186
Figure 5 – Road Lights/Lockout Keypad Indicators/Buttons 186
Troubleshooting Guide – Electrical System 187
Table 7: Electrical Troubleshooting 187
DPF (Diesel Particulate Filter) Regeneration 204
Reset Regeneration 204
Figure 1 – Reset Regeneration In- Progress 204
Figure 2 – Reset Regeneration Inhibit Button 204
Stationary Regeneration 205
Figure 3 – Stationary Regeneration Request Screen 205
Figure 4 – Stationary Regeneration 205
1 Park the machine in a safe, well-ventilated location away from flammable materials 205
2 The following conditions need to be met before stationary regeneration continues: 205
A Press the button on the control keypad or lift the operator restraint bar to apply the parking brake A check mark is displayed next to the parking brake symbol (A) 205
B When engine coolant has reached operating temperature (above 140° F / 60° C, a check mark is displayed next to the coolant temperature symbol (B) 205
C Place throttle controls to the lowest speed setting A check mark is displayed next to the engine RPM symbol when the engine is running at low idle 205
3 When all three check marks (A, B & C) are displayed on the Stationary Regeneration screen, press and hold the button (Z) until the Stationary Regeneration In-Progress screen displays 205
Figure 5 – Stationary Regeneration In-Progress Screen 205
Forcing Stationary Regeneration 206
Figure 6 – Forcing Stationary Regeneration 206
DPF Maintenance 206
Figure 7 – DPF Service Screen 206
Power Distribution Module Test and Operation 193
Engine Area Power Distribution Modules 193
WARNING 193
1 Using a volt/ohm multimeter or a test lamp, measure between test points and the chassis ground for 12 V with the wiring connected and the keyswitch in the “ON” position The test lamp lights for functioning fuses, or the volt/ohm multimeter wi 193
Heat/Wiper 193
ECU 193
Blower 193
Power Relays 194
1 With an operator in the seat and the restraint bar lowered, turning the keyswitch to the “ON” position should produce an audible “click” from each relay closing 194
2 While the keyswitch is in the “ON” position, test each relay individually, pull one relay out of the panel at a time, listening for the audible “click” of the relay opening 194
3 Plug the relay back into the panel and listen for the audible “click” of the relay re-closing, if the circuit is activated 194
4 Replace any relay for which there is no discernible “clicking” sound heard at keyed power or opening (removing) of the relay 194
5 Replace any relay that does not have continuity between powered terminals #85 and #86 194
Power Relays 194
Relays 194
1 A relay may be tested by removing it and taking it to a work bench Apply a ground to terminal #85 and a 12 V source to terminal #86 The relay should actuate There should be continuity between terminal #30 and terminal #87 194
2 Replace any relay that does not have continuity between powered terminals 194
Glow 195
Glow 195
Live Power 195
WARNING 195
1 Raise the engine cover and lock open the rear grille 195
2 Remove two protective electrical covers from the solenoids 195
3 Using a volt/ohm multimeter or a test lamp, confirm the following conditions with the wiring connected 195
4 The most forward solenoid, the engine glow circuit, will only engage when the engine ECU senses an ambient temperature below 22° F (-6° C) The engine’s ECU provides both the control current and ground for the solenoid: 195
5 For the engine starter solenoid: 195
Electrically-Controlled Standard Auxiliary Hydraulic Flow System Test and Operation 196
Standard Aux Flow Control – Rocker 196
Standard Aux Flow Control – Trigger 196
High-Flow Valve Shown 196
1 With the seat switch compressed and the restraint bar down, raise the ROPS/FOPS as described in the Operator’s Manual 196
2 Check the diode and micro-relay in the power distribution panel 196
3 Verify connections at the control handle coils and standard auxiliary control module 196
4 Ensure that the solenoid of the pilot pressure supply valve for the main control valve is receiving the 12 V signal to allow hydraulic solenoid operation from the interlock control module 196
5 The standard auxiliary hydraulic control module provides 5 V power to the rocker switch in the right- hand control grip The rocker switch in turn modulates this 5 V based on the position of the switch To verify the functional status of the rocke 196
6 The resistance across the two terminals of the solenoids coils for the standard auxiliary hydraulic system that are positioned on the main control valve can also be checked to verify that they are functional Remove the electrical connector from e 196
Engine Throttle Test and Operation 197
Hand Throttle 197
Foot Throttle – DJS and T-Bar Controls 197
1 Foot throttle: Check the resistance across pins B and C in the connector pin The resistance should measure 2 5 k ohms (W) 197
Seat Switch Removal and Installation 198
WARNING 198
1 Remove the seat from the track loader per the procedure found in the Mainframe chapter Turn the seat over 198
2 Remove the metal plate covering the seat switch 198
Seat Switch 198
3 Disconnect the electrical connector on the seat switch 198
4 Slide the seat switch in its slot until it can be freed from the seat 198
WARNING 198
Restraint Bar Switch Removal and Installation 199
WARNING 199
1 Remove the restraint bar assembly per the procedure in the Mainframe chapter 199
2 Remove the two washers and hex nuts that secure the magnet and the proximity switch to the pivot assembly bracket 199
Proximity Switch and Magnet 199
3 Remove the switches from the bracket assembly 199
WARNING 199
Master Disconnect Switch – Remote Battery Terminal Removal and Installation (Models RT165/1650RT Shown; Others Similar) 200
WARNING 200
1 Remove the battery cables from the battery Reference the “Batteries Removal and Installation” procedure in the Engine chapter 200
2 On the switch, find a small screw securing the switch knob to the switch Remove the screw from the switch and remove the knob 200
Disconnect Switch Screw 200
3 Remove the switch plate jam nut securing the switch plate and the switch into the mounting hole 200
Switch Plate Jam Nut 200
4 On the back of the disconnect switch, remove all nuts and all cables/wires attached to the disconnect switch Push the disconnect switch forward and out of the track loader 200
NOTE: 200
Front and Rear Work Light Bulb Replacement 201
WARNING 201
1 Remove four screws on the lens cover of either a front or rear work light and remove the lens cover and lens 201
2 Detach the electrical connector on the halogen bulb at the rear of the work light housing 201
3 Release the bulb retaining clips and remove the bulb 201
IMPORTANT 201
4 On white lens lights, front and rear, replace the used bulb with a new 55 W H3 bulb On red lens lights, rear-only, replace the used bulb with a new 35 W H3 bulb 201
Dome Light Bulb Replacement 201
WARNING 201
1 Climb into the cab and find dome light assembly on ceiling of the cab 201
2 Find the notches and pop the dome light lens cover out of the recessed base with a flat-tipped screwdriver 201
3 Replace the used bulb with a new GE168 bulb 201
Electrical Chassis Schematic, Page 1 of 2 207
Electrical Chassis Schematic, Page 2 of 2 208
Electrical ROPS/FOPS Schematic, Page 1 of 3 209
Electrical ROPS/FOPS Schematic, Page 2 of 3 210
Electrical ROPS/FOPS Schematic, Page 3 of 3 211
Electrical Engine Schematic, DPF Engine 212
Electrical Engine Schematic, Non-DPF Engine – Models RT165/1650RT 213
Electrical Engine Schematic, Non-DPF Engine – Models RT135/1350RT 214
Electrical Road Lights Schematic 215
Electrical HVAC Schematic 216
Electrical Track Tension Schematic 217
CHAPTER NOTES 219
ENGINE 221
Troubleshooting Guide 221
IMPORTANT 221
Table 1: Engine Troubleshooting 221
Oil Filter Element Removal and Installation 247
WARNING 247
1 Open the engine access cover and lock open the rear grille 247
2 On the left side of the engine compartment, near the air cleaner, locate the remote oil filter element 247
Engine Oil Filter Location 247
3 Place a suitable container beneath the oil filter to catch any leaking oil 247
Disposable Pan 247
4 If removing old oil, place a suitable container beneath the oil drain plug and remove the drain plug (refer to operator’s manual for details on changing oil) 247
Remote Engine Oil Drain 247
5 Clean the area around the oil filter element 247
6 Turning it counterclockwise, loosen the oil filter with a filter wrench 247
7 Turn the filter by hand until it is free of the oil filter mating surface 247
1 Clean oil filter mating surface of any debris before installing new filter element 247
2 Apply a thin film of oil to seal on filter element before installing 247
3 Hand-tighten the filter element, turning it clockwise, until gasket contacts filter mating surface, then turn the filter another 3/4 turn to seat gasket 247
4 If old oil has been removed, refill the crankcase as follows (See “SPECIFICATIONS” on page 1 chapter): 247
5 Start engine and check for leaks near oil filter Shut off engine, recheck oil level, and fill as needed 247
Air Cleaner Assembly Removal and Installation (RT165/1650RT shown; others similar) 248
WARNING 248
1 Open the engine access cover and lock open the rear grille 248
2 At the front of the air cleaner assembly, clean the area around the air cleaner hose connection 248
3 Loosen the hose clamp securing the air filter hose to the assembly and pull the hose away from the air cleaner Cover the air cleaner hose opening to help prevent contamination 248
4 Release the air cleaner clamp to release the air cleaner canister and remove the canister 248
Air Cleaner Clamp 248
5 Remove the bolts and locknuts securing the air cleaner bracket to a metal bracket and remove the air cleaner bracket 248
Air Filter Element Removal and Installation 249
WARNING 249
1 Open the engine access cover and lock open the rear grille 249
2 Release the three spring clips securing the end cap and remove the end cap Clean out any dirt build- up in the end cap 249
3 Pull the primary and secondary air filter elements from the air cleaner assembly 249
Primary Air Filter 249
Secondary Air Filter 249
4 Replace both air filter elements, if needed (See Service chapter of the Operator’s Manual ) 249
5 Check the condition of the dust ejector 249
Battery Removal and Installation 250
WARNING 250
WARNING 250
1 Open the engine access cover and lock open the rear grille 250
2 Remove the negative battery cover and then the negative ( – ) battery cable from the negative ( – ) battery post 250
RT165/1650RT shown; others similar 250
3 Remove the positive battery cover and then the positive (+) battery cables from the positive (+) battery post 250
RT165/1650RT shown; others similar 250
4 Remove one locknut and washer on each battery holddown rod and pull the holddown bracket up and out of the loader 250
RT165/1650RT shown; others similar 250
Starter Removal and Installation (RT165/ 1650RT shown; others similar) 251
WARNING 251
1 Open the engine access cover and lock open the rear grille Locate the starter at the lower right side of the engine 251
2 On the starter solenoid, remove the nut that secures the positive (+) battery cables and remove the cables 251
3 Use the quick-disconnect connector on the white wire to disconnect it from the chassis harness If replacing the starter, be sure to disconnect the white wire from the old starter for use with the new one 251
Quick Disconnect 251
4 Remove the two screws securing the starter to the engine and remove the starter 251
Exhaust Pipe Removal and Installation 252
WARNING 252
1 Open the engine access cover and lock open the rear grille 252
2 Remove four nuts and lock washers securing the exhaust pipe to the DPF canister and remove the pipe 252
Alternator Belt Adjustment 252
WARNING 252
1 Open the engine access cover and lock open the rear grille 252
2 Test the fan belt tension by pushing on the belt midway between the alternator and the engine crankshaft pulley The belt should deflect about 1/ 2” (13 mm) under a load of 20 lbs (90 N) If adjustment is needed, follow the step below 252
Location of Alternator Belt 252
3 Loosen two bolts on the alternator, one at the low pivot area and one on top of the slide bracket 252
4 Rotate the alternator in a clockwise direction (viewed from the engine end) until the correct belt tension is achieved 252
5 Retighten the bolts 252
Radiator/Cooler Removal and Installation 253
WARNING 253
1 If necessary, drain the oil from the hydraulic reservoir per the procedure in the Lubrication chapter 253
2 If necessary, drain the engine coolant from the radiator per the procedure in the Lubrication chapter 253
NOTE: 253
3 Open the engine access cover and lock open the rear grille 253
4 Swing the radiator/cooler out from the loader 253
5 Remove coolant hoses and/or hydraulic oil lines from the inlets and outlets of the radiator/cooler 253
Lower Left of Radiator/Cooler 253
Top Left of Radiator/Cooler 253
Top of Radiator/Cooler 253
6 If necessary, on the lower right area of the radiator/ cooler, temporarily disconnect the water separator bracket assembly from the chassis and move out of the way to get at the lines/hoses 253
Lower Right of Radiator/Cooler 254
7 Remove the locking capscrews on each side securing the radiator/cooler to the fan shroud 254
8 Support the radiator/cooler with a suitable hoist of adequate capacity and a positive locking mechanism able to support the radiator/cooler or equivalent 254
9 Unbolt the radiator from its pivot bracket 254
10 Remove the radiator/cooler from the track loader 254
WARNING 254
WARNING 254
11 ALWAYS check for hydraulic/coolant fluid leaks after reassembling components of the hydraulic system 254
Fan Shroud and Mounting Plates Removal and Installation 255
WARNING 255
NOTE: 255
1 Unbolt the fuel cooler bracket from the fan shroud 255
Location of Fuel Cooler 255
2 Remove all the screws on each side securing the shroud assembly to the cooler mount plate 255
RT165/1650RT shown; others similar 255
3 Support the fan shroud with a suitable hoist of adequate capacity and a positive locking mechanism able to support the fan shroud or equivalent 255
4 Remove the fan shroud from the track loader 255
5 Loosen the fasteners securing the fan shroud to the floor of the chassis and remove fan shroud and mounting plates 255
Models RT165/1650RT 255
View from Underneath Loader 255
Models RT135/1350RT 256
WARNING 256
WARNING 256
Fan Adjustment (RT165/1650RT shown; others similar) 256
WARNING 256
1 Open the engine access cover and lock open the rear grille 256
2 Loosen, but do not remove, the carriage bolts and locknuts securing the cooler mount plate to the chassis floor 256
Models RT165/1650RT 256
Models RT135/1350RT 256
3 Slide the fan shroud assembly and cooler plate mount back and forth until the front edge of the fan blades (engine side of fan) are 7/16” – 3/4” (11,2 mm – 19 mm) outside the shroud 257
4 Tighten the carriage bolts fastening the cooler mount plates to the chassis floor to secure the depth adjustment There should be a 1/2” (12,7 mm) gap all around the tips of the fan blades to the fan shroud ring 257
Fan Removal and Installation 257
WARNING 257
1 Open the engine access cover and lock open the rear grille 257
2 Swing the radiator/cooler out from the loader 257
3 Unbolt the fuel cooler bracket from the fan shroud 257
Location of Fuel Cooler 257
4 Remove all the screws on each side securing the shroud assembly to the cooler mount plate secured to the floor of the chassis 258
5 Unbolt four capscrews and washers securing the fan to the fan spacer 258
6 Carefully pull the fan up and through the opening in the shroud assembly 258
7 Repair or replace the engine fan 258
Engine Removal and Installation 258
NOTE: 258
WARNING 258
1 Drain the hydraulic oil reservoir and the engine oil 258
2 Remove the engine access covers per the procedure in the Mainframe chapter 258
3 Remove the rear grille per the procedure in the Mainframe chapter 258
4 Remove the ROPS/FOPS per the procedure found in the Mainframe chapter 258
5 Remove the battery per the procedure in this chapter 258
6 Remove the lift and tilt controls from the hydrostatic pump per the procedures found in the Controls chapter 258
7 Remove the air cleaner assembly per the procedure in this chapter 258
WARNING 259
8 Remove the exhaust assembly per the procedure in this chapter 259
9 Remove the radiator/cooler per the procedure in this chapter 259
10 Remove the fan and fan shroud per the procedure in this chapter 259
11 Unbolt the remote oil filter assembly from the chassis 259
IMPORTANT 259
12 At the electrical connector end, unplug the electrical plug cord for the engine heater (orange cap on engine, if so equipped) 259
13 Turn the water separator fuel supply petcock to its OFF position 259
14 Remove two fuel lines on the engine’s fuel filter mount assembly 259
15 Unplug the electrical connector on the fuel pump 259
Fuel Pump 259
16 Disconnect the engine harness and the four electrical engine connectors at lower left side of the engine 260
17 At lower right front of the engine block, disconnect the negative ( – ) ground cable from the right chaincase area 260
NOTE: 260
NOTE: 260
18 Label and disconnect all the hydraulic hoses connected to the hydrostatic pump Refer to the “Hydrostatic Pump Removal” procedure in the Hydrostatic System chapter for hydraulic hose removal procedure on the pump 260
19 If equipped with air conditioning: Evacuate the freon from the HVAC lines and drain the coolant before disconnecting two hydraulic lines from their bracket 260
20 Through the rear belly pan, disconnect the remote oil drain hose from the engine oil pan 260
21 Attach lift hooks to engine lifting locations on the front and rear of the cylinder head 260
Front Engine Lift Hook 260
22 Remove one carriage bolt, hex nut (110 lbf-ft) (149 N•m), a rubber isolator and two large washers on the four engine mounts When reinstalling, use Loctite® 242 (or equivalent) 260
23 With the hoist attached to the engine, lift slightly and pull the engine and pump rearward Remove the engine from the chassis 261
WARNING 261
WARNING 261
Engine Diagnostic Data Port 262
Data Port for Engine 262
Yanmar Engine Diagnostic Fault Codes 0
Table 2: Yanmar Engine Diagnostic Trouble Codes (DTC) 262
Parts Listing for DPF Engine Illustration On Previous Page 225
Parts Listing for DPF Engine Illustration On Previous Page 227
Parts Listing for Non-DPF Engine Illustration On Previous Page 233
Parts Listing for DPF Engine Illustration On Previous Page 227
Parts Listing for Non DPF Engine Illustration On Previous Page 235
Parts Listing for DPF Engine Illustration On Previous Page 235
Parts Listing for DPF Engine Illustration On Previous Page 229
Parts Listing for DPF Engine Illustration On Previous Page 229
Parts Listing for DPF Engine Illustration On Previous Page 231
Parts Listing for DPF Engine Illustration On Previous Page 231
Parts Listing for Non DPF Engine Illustration On Previous Page 237
Parts Listing for DPF Engine Illustration On Previous Page 237
Parts Listing for Non DPF Engine Illustration On Previous Page 239
Parts Listing for DPF Engine Illustration On Previous Page 239
Parts Listing for Non DPF Engine Illustration On Previous Page 241
Parts Listing for DPF Engine Illustration On Previous Page 241
Parts Listing for Non DPF Engine Illustration On Previous Page 243
Parts Listing for DPF Engine Illustration On Previous Page 243
INDEX 271