Cat 920 930 Wheel Loaders System

FORM NO.
REG00976-01
FOR USE IN MANUAL:
920, 930 WHEEL LOADERS,
FORM REG00514
DISASSEMBLY AND ASSEMBLY
920 & 930 WHEEL LOADERS

VEHICLE SYSTEMS
SERIAL NUMBERS:
920-41J, 75J, 62K
930-71H, 79J, 41K, 73U
BDC for engine manuals and specs

https://barringtondieselclub.co.za/
VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY
A WARNING
IMPORTANT SAFETY NOTICE
Proper repair is important to the safe and reliable operation of a machine. This
Service Manual outlines basic recommended procedures, some of which require
special tools, devices or work methods. Although not necessarily all inclusive, a list
of additional skills, precautions and knowledge required to safely perform repairs is
provided in the SAFETY section of this Manual.
Improper repair procedures can be dangerous and could result in injury or death.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE
Basic safety precautions, skills and knowledge are listed in the SAFETY section
of this Manual and in the descriptions of operations where hazards exist. Warning
labels have also been put on the machine to provide instructions and identify
specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained
mechanic. There are many potential hazards during repair for an untrained
mechanic and there is no way to label the machine against all such hazards. These
warnings in the Service Manual and on the machine are identified by this symbol:
A WARNING
Operations that may result only in machine damage are identified by labels on the
machine and in the Service Manual by the word CAUTION.
Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this Manual are therefore not all inclusive. If a
procedure, tool, device or work method not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and others. You
should also ensure that the machine will not be damaged or made unsafe by the
procedures you choose.
67200X1
A WARNING
DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK.

A WARMING
SAFETY
A WARNING A WARNING
The proper and safe lubrication and mainte Do not operate this machine unless you have
nance procedures for this machine, recom read and understand the instructions in the
mended by Caterpillar, are outlined in the OPERATOR’S GUIDE. Improper machine oper
LUBRICATION & MAINTENANCE GUIDE for ation is dangerous and could result in injury or
this machine. death.
Improper performance of lubrication or

maintenance procedures is dangerous and
could result in injury or death. Read and under
stand the LUBRICATION & MAINTENANCE
GUIDE before performing any lubrication or 3. Disconnect battery and discharge any capacitors
maintenance. before starting to work on machine. Hang “Do
Not Operate” tag in the Operator’s compartment.
4. If possible, make all repairs with the machine
parked on a level, hard surface. Block machine so
it does not roll while working on or under
machine.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it 5. Do not work on any vehicle that is supported only
important to use caution when performing service by lift jacks or a hoist. Always use blocks or jack
work. A knowledge of the system and/or component is stands to support the vehicle before performing
important before the removal or disassembly of any any disassembly.
component.
6. Relieve all pressure in air, oil or water systems
Because of the size of some of the machine compo before any lines, fittings or related items are dis
nents, the serviceman or mechanic should check the connected or removed. Always make sure all
weights noted in this Manual. Use proper lifting proce raised components are blocked correctly and be
dures when removing any components. alert for possible pressure when disconnecting any
device from a system that utilizes pressure.
Following is a list of basic precautions that should
always be observed. 7. Lower the bucket, blade, ripper or other imple
ments to the ground before performing any work
1. Read and understand all Warning plates and decals on the machine. If this cannot be done, make sure
on the machine before operating, lubricating or the bucket, blade, ripper or other implement is
repairing the machine. blocked correctly to prevent it from dropping un
expectedly.
2. Always wear protective glasses and protective
shoes when working around machines. In particu 8. Use steps and grab handles when mounting or
lar, wear protective glasses when pounding on any dismounting a machine. Clean any mud or debris
part of the machine or its attachments with a ham from steps, walkways or work platforms before
mer or sledge. Use welders gloves, hood/goggles, using. Always face machine when using steps,
apron and other protective clothing appropriate to ladders and walkways. When it is not possible to
the welding job being performed. Do not wear use the designed access system, provide ladders,
loose-fitting or tom clothing. Remove all rings scaffolds, or work platforms to perform safe repair
from fingers when working on machinery. operations.

A WARMING
9. To avoid back injury use a hoist when lifting 14. Reinstall all fasteners with same part number. Do
components which weigh 50 lb. (23 kg) or more. not use a lesser quality fastener if replacements are
Make sure all chains, hooks, slings, etc., are in necessary.
good condition and are in the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes 15. Repairs which require welding should be per
are not to be side loaded during a lifting operation. formed only with the benefit of the appropriate
reference information and by personnel
10. To avoid bums, be alert for hot parts on machines adequately trained and knowledgeable in welding
which have just been stopped and hot fluids in procedures. Make reference to “Techniques of
lines, tubes and compartments. Structural Repair Course” form number
JEG03719. Determine type of metal being welded
11. Be careful when removing cover plates. Gradually and select correct welding procedure and elec
back off the last two bolts or nuts located at oppo trodes, rods or wire to provide a weld metal
site ends of the cover or device and pry cover loose strength equivalent at least to that of parent metal.
to relieve any spring or other pressure, before
removing them completely. 16. Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
12. Be careful when removing filler caps, breathers be damaged in operation by contacting sharp cor
and plugs on the machines. Hold a rag over the cap ners, or by rubbing against some object or hot
or plug to prevent being sprayed or splashed by surface. Do not connect wiring to a line containing
liquids under pressure. The danger is even greater fluid.
if the machine has just been stopped because fluids
can be hot. 17. Be sure all protective devices including guards and
shields are properly installed and functioning cor
13. Always use tools that are in good condition and be rectly before starting a repair. If a guard or shield
sure you understand how to use them before per must be removed to perform the repair work, use
forming any service work. extra caution.
m CATERPILLAR
Caterpillar, Cat and tH are Trademarks of Caterpillar Tractor Co.

GENERAL TIGHTENING TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS :-----------
The following charts give the standard torque values for bolts, nuts [J
and taperlock studs of SAE Grade 5 or better quality. Exceptions are
given in other sections of the Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb. ft. N-m*
Standard thread
’mrrrmrrrh. Use these torques for bolts and nuts with stan-
—r
dard threads (conversions are approximate).
L ID
1/4 6.35 9 ±3 12 ± 4
5/16 7.94 18 ±5 25 ±7
3/8 9.53 32 ±5 45 ±7
7/16 11.11 50 ± 10 70 ± 15
1/2 12.70 75 ± 10 100 ± 15
9/16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ±20 200 ± 25
3/4 19.05 265 ± 35 360 ± 50
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ± 80 875 ±100
11/8 28.58 800 ±100 1100 ±150
1 1/4 31.75 1000 ±120 1350 ±175
1 3/8 34.93 1200 ±150 1600 ± 200
1 1/2 38.10 1500 ±200 2000 ± 275
Use these torques for bolts and nuts on

hydraulic valve bodies.
5/16 7.94 13 ±2 20 ± 3
3/8 9.53 24 ±2 35 ±3
7/16 11.11 39 ±2 50 + 3
1/2 12.70 60 ±3 80 ±4
5/8 15.88 118 ±4 160 ± 6
Taperlock stud
Use these torques for studs with Taperlock threads.
1/4 6.35 5 2 ± 7+3

5/16 7.94 10 3 ± 15 ± 5
3/8 9.53 20 ±3 30 ±5
7/16 11.11 30 ±5 40 ± 10
1/2 12.70 40 ±5 55 ± 10
9/16 14.29 60 10± 80 ± 15
5/8 15.88 75 ± 10 100 ± 15
3/4 19.05 110 ± 15 150 + 20
7/8 22.23 170 ± 20 230 ± 30
1 25.40 260 ± 30 350 ± 40
1 1/8 28.58 320 ± 30 400 ± 40
1 1/4 31.75 400 ± 40 550 ± 50
1 3/8 34.93 480 ± 40 650 ± 50
1 1/2 38.10 550 ± 50 750 + 70
*1 newton meter (N-m) is approximately the same as 0.1 mkg.

VEHICLE SYSTEMS
INDEX
Air Tank......................................................................................................................
...... 23
Brake Control Valves................................................................................................. ......... 7

Brake Control Valves, Disassemble & Assemble...................................................... .... 8-11
Brake Head Assemblies............................................................................................. ...... 17
Brake Head Assemblies, Disassemble & Assemble................................................. .. 18,19
Brake Master Cylinder Actuators............................................................................... ...... 12
Brake Master Cylinder Actuators, Disassemble & Assemble................................... ...... 13
Brake Master Cylinders............................................................................................. ...... 14
Brake Master Cylinders, Disassemble & Assemble................................................. .. 14,15
...... 53
Bucket........................................................................................................................
...... 54
Bucket Positioner......................................................................................................
Bucket Positioner, Disassemble & Assemble........................................................... .. 55,56
Bucket Positioner Master Cylinder............................................................................ ...... 57
Bucket Positioner or Lift Kickout Master Cylinder, Disassemble & Assemble .. 58-61
Bucket Positioner and Lift Kickout Slave Cylinders.................................................. ...... 61
Bucket Positioner or Lift Kickout Slave Cylinder, Disassemble & Assemble.. .. 62,63
102,103
Cab............................................................................................................................
Emergency and Parking Brake Control Valve.......................................................... .. 20,21
Emergency and Parking Brake Control Valve, Disassemble & Assemble............... ... 21,22
... 23,24
Emergency and Parking Brake Chamber.................................................................
Emergency and Parking Brake Chamber, Disassemble & Assemble..................... .. 25-27
.. 28-30
Emergency and Parking Brake.................................................................................
... 90-93
Hydraulic Tank..........................................................................................................
... 78-80
Hydraulic Control Valve............................................................................................
Hydraulic Control Valve, Disassemble & Assemble................................................. ... 81-84
... 94,95
Hydraulic Pump.........................................................................................................
. 96-101
Hydraulic Pump, Disassemble & Assemble.............................................................
... 75-77
Lift Arms....................................................................................................................
... 64,65
Lift Cylinders.............................................................................................................
Lift Cylinders, Disassemble & Assemble................................................................. ... 66-70
....... 58
Lift Kickout Master Cylinder.....................................................................................
... 86,87
Lift and Tilt Control Lever Housings.........................................................................
Lift and Tilt Control Lever Housings, Disassemble & Assemble............................. ... 87-89
104-109
Loader Main Frames................................................................................................
....... 85
Make-Up Valve.........................................................................................................
110-113
Pivot Pin Bearings....................................................................................................
........... 6
Rim and Tire.............................................................................................................
.... 31,32
Steering Column......................................................................................................
Steering Column, Disassemble & Assemble........................................................... ... 32-35
........ 35
Steering Metering Unit.............................................................................................
Steering Metering Unit, Disassemble & Assemble.................................................. .... 36-39
......... 40
Steering Control Valve.............................................................................................
Steering Control Valve, Disassemble & Assemble................................................. .... 41-46
Steering Cylinders.................................................................................................... .... 47-49
Steering Cylinders, Disassemble & Assemble........................................................ .... 49-52
......... 31
Steering Wheel...........................................................................■'..........................
... 70, 71
Tilt Cylinders............................................................................................................
Tilt Cylinders, Disassemble & Assemble................................................................. .... 72-75
......... 20
Wheel Brake Discs..................................................................................................
......... 16
Wheel Brake Linings...............................................................................................

A58737X1

RIM AND TIRE

REMOVE AND INSTALL RIM
AND TIRE 4202-10
Tools Needed A
8S7640 Stand 2
8S7611 Tube 2
8S7615 Pin 2
8S8048 Saddle 2
NOTE: The bucket is removed for better photo illustra

tion of the tooling position.
CAUTION:
Before the machine is lifted, make sure the
parking brake is engaged and blocks are in
front and behind the tires on the opposite end
of the machine.
1. Lift the machine and put tooling (A) in position

under the axle housing as shown.
2. Fasten a hoist to the tire.
3. Remove nuts (1) and remove the rim and tire.

The weight of the rim and tire without fluid is:
920-320 lb. (144 kg).
930-420 lb. (189 kg).
4. Fasten a hoist to the rim and tire and put it in

position on the wheel assembly.
5. Install nuts (1) and tighten them to a torque of

365 ± 50 lb.ft. (490 ± 70 N-m).
6. Lift the machine and remove tooling (A). Lower

the machine to the ground.
7. See LUBRICATION AND MAINTENANCE

GUIDE for correct tire inflation.

BRAKE CONTROL VALVES

REMOVE BRAKE CONTROL %
VALVES 4265-11
A WARNING
Open the drain valve on the air tank and re
move the pressure from the air system before
any lines are disconnected.
NOTE: The right brake control valve is shown, use the

same procedure for the left brake control valve.
I. Put identification on electric wires (l) as to their

location and disconnect them from the solenoid.
2. Disconnect the four airlines (3), (4), (5) and (one

not shown) from valve assembly (2).
3. Remove the pin that holds pin (7). Remove pin

(7) and treadle assembly (6).
4. Remove boot (9) from the valve assembly. Re

move the three bolts (8) and remove the valve
assembly from the bottom of the floor plate.
INSTALL BRAKE CONTROL

VALVES 4265-12
1. Put valve assembly (1) in position and install the

three bolts that hold it in position.
2. Connect air lines (2) and (3) to valve assembly

0).
3. Connect the electric wires to their correct loca

tion on the solenoid.

4. Install the boot on the valve assembly.
5. Put treadle assembly (5) in position and install

pin (4). Install the pin that holds pin (4).
6. Start the engine and inspect the system for leaks.
DISASSEMBLE BRAKE CONTROL

VALVES 4265-15
Tools Needed A
1P1861 Pliers 1
start by:
a) remove brake control valves
NOTE: Steps l, 2 and 3 are for the right side brake

control valve only.
1. Remove stop light switch (4) and the fitting from

double check valve (2). Remove check valve (1)
and double check valve (2) from valve body (3).
2. Remove cap (5), spring (8), disc (6), seat (9) and
washer (7) from the check valve.
NOTE: The parts of check valve (1) can not be ordered

separately. If the parts have wear or damage a replace
ment of the valve is necessary.
3. Remove cap (12), gasket (11), retainer and seat

assembly (10) from the double check valve. A55482X1

4. Remove retainer (13) from valve body (3).
5. Remove piston assembly (14) and spring (15)

from brake valve body (3).
6. Remove O-ring seal (19), bolt (17), washer (18),

seat (16) and spring (not shown) from piston as29z3X2
body (20).
A WARNING
Spring on valve assembly (23) is under com

pression.
7. Turn the brake valve body over as shown. Re

move ring (21) with tool (A). Remove washer
(22) and valve assembly (23).
8. Twist valve (28) and pull it away from seat (24).

Remove spring (30), retainer (29) and O-ring
seal (not shown) from valve (28).
9. Remove screw (26), washer (25), diaphram (27)

and spring (not shown) from seat (24).
A 5 29 26X2


ASSEMBLE BRAKE CONTROL
VALVES 4265-16
Tools Needed A
1P1861 Pliers 1
1. Clean all metal parts in nonflammable solvent.
2. Install spring (6), diaphram (7), the washer and

screw (8) in the large end of seat (5).
3. Install retainer (2), O-ring seal (3) and spring (4)

on valve (1). Push the valve in the small end of
seat (5) until spring (6) holds the valve in the seat.
4. Install O-ring seal (10) and valve assembly (9) in

brake valve body (11). Put the washer in position
and use tool (A) to install the ring that holds valve
assembly (9) in position.
5. Install rubber spring (13), seat (14), the washer

and bolt (15) in piston body (12). Install O-ring
seal (16) on the piston body.
6. Install spring (17) and piston assembly (18) into

brake valve body (11).
10

7. Push down on the piston assembly and install

retainer (19).
8. Install retainer and seat assembly (20), gasket

(21) and cap (22) in the double check valve.
9. Install washer (25), seat (27), disc (24), spring

(26) and cap (23) in the check valve.
10. Install double check valve (29) on valve body

(11). Install stop light switch and the fitting on
double check valve (29).
11. Install check valve (28) on double check valve

(29).
end by:
a) install brake control valves A554S3X t
11

BRAKE MASTER CYLINDER ACTUATORS

REMOVE BRAKE MASTER CYLINDER
ACTUATORS 4266-11
A WARNING
move the air pressure from the system before
1. Remove tube assemblies (1) and (2) from the

machine as a unit.
2. Remove the nuts that hold actuators (3) in posi

tion and remove.
INSTALL BRAKE MASTER CYLINDER

ACTUATORS 4266-12
1. Put actuator (1) in position. Make sure the rod

assembly is engaged correctly in the master cy
linder and install the nuts that hold it.
2. Install tube assemblies (2) on the machine.
12

BRAKE MASTER CYLINDER ACTUATORS

DISASSEMBLE BRAKE MASTER
CYLINDER ACTUATORS 4266-15
start by:
a) remove brake master cylinder actuators
1. Put marks on plate assembly (1), band assembly

(2) and chamber assembly (3) for correct align
ment at assembly.
A WARNING
Plate assembly (1) and chamber assembly (2)
have spring tension on them. Hold these parts
together when band assembly (2) is removed.
2. Remove the bolts and nuts to remove band as

sembly (2).
3. Remove chamber assembly (3), spring (4), rod
assembly (5) and diaphram (7) from plate assem
bly (1).
4. Remove indicator (6) from rod assembly (5).
ASSEMBLE BRAKE MASTER

CYLINDER ACTUATORS 4266-16
1. Install diaphram (2) in plate assembly (1).
2. Install indicator (4) on rod assembly (3). Put rod

assembly (3) in position on diaphram (2) and
install spring (7) on the rod assembly. Make sure
the small end of the spring is engaged correctly
with the base of indicator (4). A53917X1
3. Make an alignment of the marks on plate assem

bly (1) and chamber assembly (6). Make sure
indicator (4) is through the hole in the chamber
assembly and put the unit under compression.
4. Install band assembly (5) to hold the unit to

gether.
end by:
a) install brake master cylinder actuators
13

BRAKE MASTER CYLINDERS

REMOVE BRAKE MASTER
CYLINDERS 4258-11
start by:
a) remove brake master cylinder actuators
1. Remove the cap from the main brake fluid reser

voir. Remove tube assembly (1) from the
machine and drain the reservoir.
2. Remove tube assembly (3) from the machine.
3. Remove the cap from master cylinder (2). Dis

connect brake line (4) and drain the master cylin
der.
4. Remove the bolts and nuts that hold master cy

linder (2) in position and remove the master cy
linder.
INSTALL BRAKE MASTER

CYLINDERS 4258-12
Tools Needed A
9S9149 Wrench 1
1. Install the cap on master cylinder (1) and put it in

position on the machine. Install the bolts and nuts
that hold it.
2. Connect brake line (2) to the master cylinder.
3. Install the tube assembly that connects the two
master cylinders.
4. Install the tube assembly that connects the brake
fluid reservoir to the master cylinders.
end by:
a) install brake master cylinder actuators
b) use tool (A) and remove (bleed) the air from
the brake system (See HYDRAULIC
BRAKE SYSTEM SERVICING in TEST
ING AND ADJUSTING)
DISASSEMBLE BRAKE MASTER A53907X1
CYLINDERS 4258-15
start by:
a) remove brake master cylinders
1. Remove boot (2) from cylinder assembly (3).

Remove retainer (1) from boot (2).
14

BRAKE MASTER CYLINDERS
2. Remove lockwire (5), plate (6), piston assembly

(7), cup (8) and spring assembly (9) from the
cylinder assembly.
3. Remove fitting (4). the plug assembly and gasket

from the cylinder assembly.
NOTE: A master cylinder rebuild kit is available. The

kit includes a gasket, boot, seal, cup. piston assembly
and lockwire. When the master cylinder is disassem
A53908X1
bled for service, always install a repair kit.
ASSEMBLE BRAKE MASTER

CYLINDERS 4258-16
NOTE: When the hydraulic brake, system is serviced

use caution to prevent introduction of foreign material
into the brake fluid. Damaged or worn rubber parts are
an indication of other fluids in the brake system. Flush
and clean the system with denatured alcohol or clean
brake fluid.
1. Put clean brake fluid on the inside parts of the

master cylinder at assembly.
2. Inspect the bore in the master cylinder. Use a

brake cylinder hone to remove any rough areas or
corrosion in the master cylinder bore. If the cy
linder bore has deep scratches a replacement of
the master cylinder is needed.
3. Make sure the master cylinder bore is clean.

4. Install the gasket and plug assembly (1) in cylin
der assembly (2).
5. Install spring (7) as shown. Install cup (6) with

the open end toward spring (7).
6. Install piston assembly (5) as shown. Install plate

(4) and lockwire (3).
CAUTION
Make sure lockwire (3) is fitted correctly in the
groove of the master cylinder and piston as
sembly (5) returns against plate (4).
7. Install the retainer in boot (8) and install the boot
on cylinder assembly (1).
end by:
a) install brake master cylinders AS39SOX1
15

WHEEL BRAKE LININGS

REMOVE WHEEL BRAKE
LININGS 4254-11
Tools Needed A B C
8S7630 Stand 1
8S7641 Tube 1
8S8048 Saddle 1
8S7615 Pin 1
9S9149 Wrench 1
FT1048 Brake Anchor Pin Puller 1
1. Move the machine until the valve stem opening

in the tire rim is in alignment with the top anchor
pin in the brake head assembly.
2. For the front wheel brake linings, lift the bucket
and put tooling (A) in position under the lift arm
for support. Move the control lever and lower the
weight of the lift arms and bucket on tooling (A)
as shown.
3. Open the bleed valves with tool (B) to release any
pressure on the brake pistons. Push the pistons
into the head assembly to remove the pressure on
the brake linings.
CAUTION
To prevent damage to pistons and seals, do not
make an application of the brakes when the
brake linings are removed. The pistons must
not move out of their bores as the brake linings
are removed. If the pistons and seals move out
of their bores, the brake head assembly must
be removed to install the pistons.
4. Loosen bolts (1) that hold the anchor pins in

position.
5. If necessary use tool (C) to pull the anchor pins
out of the head assembly .75 in. (19.1 mm)
approximately.
6. Remove the brake linings.
INSTALL WHEEL BRAKE
LININGS 4254-12
Tools Needed A B C
8S7630 Stand 1
8S7641 Tube 1
8S8048 Pin 1
8S7615 Saddle 1
9S9149 Wrench 1
FT 1048 Brake Anchor Pin Puller 1
1. Push the brake pistons into the brake head as

sembly. This gives clearance for the new brake
linings.
2. Install brake linings (1) in the brake head assem
bly.
16

WHEEL BRAKE LININGS, BRAKE HEAD ASSEMBLIES

3. Push anchor pins (3) into the brake head assem 5. Use tool (B) and remove (bleed) the air from the
bly. hydraulic brake system. See HYDRAULIC
BRAKE SYSTEM SERVICING in TESTING
4. Make sure there is .010 in. (.25 mm) or more AND ADJUSTING.
distance between the anchor pins and wheel disc. 6. For the front brake linings, remove tooling (A)
Tighten bolts (2) to hold the anchor pins. and lower the bucket to the ground.
REMOVE AND INSTALL BRAKE HEAD

ASSEMBLIES 4256-10
Tools Needed A
9S9149 Wrench 1
start by:
a) remove rim and tire
1. Disconnect brake line (2) from brake head as
sembly (1).
2. Remove the bolts that hold the top anchor pins in
position.
3. Install two 3/8’’-16 NC forged eyebolts in the
brake head assembly and fasten a hoist as shown.
NOTE: If necessary, push the brake linings from the
wheel disc to remove the brake head assembly.
4. Remove bolts (3) that hold the brake head as
sembly to the axle housing. Remove brake head
assembly (1). The weight of the brake head as
sembly is:
920-60 lb. (27 kg)
930-90 lb. (41 kg)
CAUTION
The two anchor pins and brake linings are free
to fall out of the brake head assembly and must
be held in position when it is removed or instal
led.
5. Fasten a hoist to brake head assembly (1) with

two 3/8''-16 NC forged eyebolts.
6. Put the brake head assembly in position on the
machine and tighten bolts (3) to a torque of 225 ±
25 lb.ft. (300 ± 35 N-m).
7. Remove the forged eyebolts and hoist from the
brake head assembly.
8. Push anchor pins (5) into the brake head assem
10. Use tool (A) and remove (bleed) the air from the
bly. Make sure there is .010 in. (.25 mm) ormore
hydraulic brake system. See HYDRAULIC
distance between the anchor pins and wheel disc.
BRAKE SYSTEM SERVICING in TESTING
Install bolts (4) to hold the anchor pins.
AND ADJUSTING,
9. Connect brake line (2) to the brake head assem end by:
bly. a) install rim and tire
17

BRAKE HEAD ASSEMBLIES

DISASSEMBLE BRAKE HEAD
ASSEMBLIES 4256-15
start by:
a) remove brake head assemblies
l. Loosen bolts (2) that hold pins (3) in position and A45910X1
push pins (3) out to remove brake linings (1).
2. Remove bolts (5) and caps (4).
A45902X1
3. Remove four pistons (6) and the boots from the

brake head assembly.
4. Remove the boots from the pistons and the seals A45 9 04X1
from the piston bores.
ASSEMBLE BRAKE HEAD

ASSEMBLIES 4256-16
Tools Needed A
5P3569 Piston Press 1 ■
1P495 Drive Plate 1
1. Install seals (1) in the four piston bores.
2. Install boots (2) in the piston bores with the lip of

the boot in the groove of the bore. A45906X1
18

BRAKE HEAD ASSEMBLIES

3. Install the four pistons (3) in the bores of the
brake head through the boots.
CAUTION: The ends of the pistons must be through the

boots before the pistons are pushed into the bores or the
damage to the boots will be the result. A45907X
4. Use tooling (A) to push the pistons in the bores.

Put the lip of the boots in the groove of the
pistons.
5. Install the O-ring seals on the two caps (4) and

install the caps on the brake head.
6. Put brake linings (5) in position and push pins (7)

in to hold them. Tighten bolts (6) to hold the pins,
end by:
a) install brake head assemblies A459I0X2
19

WHEEL BRAKE DISCS, EMERGENCY AND

PARKING BRAKE CONTROL VALVE
REMOVE AND INSTALL WHEEL
BRAKE DISCS 4255-10
start by:
a) remove wheel assemblies, bearings and
seals*
1. Remove bolts (1).

2. Remove wheel brake disc ( 2 ) .
3. Put wheel brake disc (2) in position on the wheel
assembly.
4. Install the bolts that hold the disc to the wheel
assembly and tighten them to a torque of 195 ±
20 lb.ft. (265 ± 25 N-m).
end by:
a) install wheel assemblies, bearings and seals*
*These operations are in the POWER TRAIN DISAS

SEMBLY AND ASSEMBLY section.
REMOVE EMERGENCY AND PARKING

BRAKE CONTROL VALVE 4282-11

CAUTION
The disconnect switch must be in the “OFF”
position before the dash assembly is moved.
1. Remove the six bolts (l) that hold the dash as
sembly in position. Pull the dash assembly to the
steering column.
2. Remove pin (6) from knob (4) and remove the
knob from the valve.
3. Disconnect pipe (2) from the valve. Disconnect
the air line (5) from the elbow on pipe (2).
4. Remove nut (3) and pull the valve out a small
distance.
5. Put identification on the two wires as to their
location on the air pressure indicator [found at the
end of pipe (2)] and disconnect them.
6. Remove the valve and air pressure indicator as a
unit.
20

EMERGENCY AND PARKING BRAKE CONTROL VALVE

INSTALL EMERGENCY AND PARKING
1. Put valve (1) and the air pressure indicator (2) in

position on the machine.
2. Connect the two electric wires to their correct

location on air pressure indicator (2).
3. Install the nut to hold valve (1) in position. Install

the knob and pin on the valve.
4. Connect air line (3) to the valve. Connect the

second air line to the elbow for the air pressure
indicator.
5. Put dash assembly (4) in position and install the

six bolts to hold it.
DISASSEMBLE EMERGENCY AND PARKING

start by:
a) remove emergency and parking brake control
valve 1
1. Remove screws (2) from valve body (1). Re

move cover (3).
21

AIR TANK, EMERGENCY AND PARKING BRAKE CHAMBER

REMOVE AND INSTALL AIR
TANK 4272-10
A WARNING
1. Disconnect air lines (1) and (2) from the air tank.
2. Remove the four bolts (3) and remove the air

tank.
3. Put air tank (4) in position. Install the clamps and

bolts (3) to hold the air tank.
4. Connect air lines (1) and (2) to the air tank.
REMOVE AND INSTALL EMERGENCY

AND PARKING BRAKE
CHAMBER 4278 & 4262-10
1. Turn the machine all of the way to the left.
2. Lower the bucket to the ground and put blocks in
front and behind the wheels.
3. Remove the bolt and washer from pin (1). Re
move pin (1) from the top of the frame.
4. Turn the steering wheel to the right several turns
to pull rod (2) into the steering cylinder.
A WARNING
Keep hands away from the brake chamber area
until the emergency brake has been released.
5. Push the emergency brake control (found on the

dash) to release the emergency brake.
NOTE: Shop air pressure of 70 psi (4.9 kg/cm1 2 3 4) or (480

kPa) can be used to activate the parking brake chamber.
23

EMERGENCY AND PARKING BRAKE CHAMBER

6. Remove the cotter pin and pin (3).
A WARNING
any air lines are disconnected.
7. Disconnect air line (7) for the brake chamber at

tube connection (6). Remove air line (7) from the
brake chamber.
8. Remove bolts (4) that hold bracket (5) in posi
tion.
9. Disconnect bracket (5) from brake chamber (8)
and remove the air chamber and bracket from the
machine.
10. Put brake chamber (8) in position between the
frame and transmission. Connect bracket (5) to
the brake chamber.
11. Install bolts (4) to hold bracket (5) in position.
12. Connect air line (7) to the brake chamber and
tube connection (6).
13. Close the drain valve on the air tank. Start the
engine to increase the pressure in the air system.
Stop the engine.
A WARNING

until the rod is in position.
14. Pull the emergency brake control (found on the

dash) to push the rod into position. Install pin (3)
and the cotter pin.
15. Turn the steering wheel several turns to move rod
(2) into position. Make sure the washers are
installed on both sides of the rod. Install pin (1)
and the bolt and washer that hold the pin.
16. Make an adjustment of the emergency brake. See
EMERGENCY AND PARKING BRAKE AD
JUSTMENT' in TESTING AND ADJUST
MENT in TESTNG AND ADJUSTING for this
procedure.
24


DISASSEMBLE EMERGENCY AND PARKING
BRAKE CHAMBER 4278 & 4262-15
Tools Needed A
8H684 Ratchet Box Wrench 1
8F3672 Plate 1
8B7548 Puller Assembly 1
8B7549 Leg 2
start by:
a) remove emergency and parking brake
chamber A50055X t
1. Remove yoke (1) and two adjusting nuts (2) from

the rod.
2. Remove two bolts (3) one on each side of

chamber. Remove retaining ring (4) from the
rubber boot.
3. Install the chamber in tooling (A). Put force

down on the top of the chamber with the puller
screw. Remove the remainder of bolts (5) around
the base of the chamber.
A WARNING
The large spring inside of chamber is under 900
lb.(4000 N)force.
4. Gradually release spring (6) as the puller screw is

turned counterclockwise until all spring force is
gone. Remove the chamber from tooling (A).
5. Remove base assembly (7), the spring and rod

assembly (8) from cylinder (9).
A0669SX2
A062S9X3
25


6. Remove large and small springs (10) from the
rod. Remove felt and rubber seals (11) from the
bases of the rod. Inspect the two seals and make
replacements if necessary.
7. Remove rubber boot (13) and O-ring seal (12)

from the base assembly. Check the condition of
the seal. If the seal has damage, use new parts for
replacement.
A06285X2
ASSEMBLE EMERGENCY AND PARKING

BRAKE CHAMBER 4278 & 4262-16
Tools Needed A
8F3672 Plate 1
8B7549 Leg 2
1. Install a new O-ring seal (1) on base assembly.

Install rubber boot (2) on base assembly.
2. Install a new rubber and felt seal (4) on base of

the rod. Install small and large springs (3) on the
rod.
26


3. Install base assembly (5), spring and rod assem
bly (6) into cylinder (7).
4. Put chamber into position in tooling (A) and put

it under compression. Install all but two of the
bolts (8). Remove chamber from tooling (A).
5. Install the other two bolts (10) on each side of

chamber. Install retaining ring (9) on the rubber
boot.
A0fi290X2
6. Install two adjusting nuts (12). Install yoke (11)

on the rod.
end by:
a) install emergency and parking brake chamber A5Q055X2
27

EMERGENCY AND PARKING BRAKE

REMOVE EMERGENCY AND PARKING
BRAKE 4267-11
Tools Needed A
Brake Pliers 1
start by:
a) remove steering control valve
A55466X1
1. Turn the machine all of the way to the left. Put

blocks in front and behind the wheels.
2. Drain the oil from the transmission. The capacity

of the transmission is 6.75 U.S. gal. (25.5 litre).
3. Remove the bolts that hold each end of inter

mediate drive shaft (1) and remove the drive
shaft.
A WARNING **
m %.

until the parking brake has been released. 4 5 6 7
4. Push the emergency brake control (found on the A55468X1
dash) to release the parking brake.
NOTE: If necessary, use shop air pressure of 70psi (4.9

kg/cm2) or (480 kPa) to release the parking brake.
5. Remove the cotter pin and pin (2).
6. Remove the six bolts and remove brake drum (3).
7. Remove the bolt, retainer (5), the O-ring seal and

flange (4). A55469X1


8. Remove bolts (6) and remove the parking brake
group and camshaft assembly from the machine.
9. Use tool (A) to remove springs (8). Remove

brake shoes (7) from plate assembly (9).
INSTALL EMERGENCY AND PARKING

BRAKE 4267-12
Tools Needed A
Brake Pliers 1
1. Connect brake shoes (2) together with spring (4).
a
2. Put brake shoes (2) in position on plate assembly *
A4720IX!
(3).
3. Use tool (A) to install two springs (1). 4
4. Put camshaft assembly (5) and the brake group in

position on the output transfer gears case and
install the four bolts and lockwashers to hold
them.
1X1
29


5. Put flange (6) in position.
6. Install the O-ring seal, retainer (8) and bolt to

hold flange (6) in position. Tighten the bolt to a
torque of 80 ± 5 lb.ft. (110 ± 7 N-m).
7. Put brake drum (7) in position and install the six

bolts to hold it. Tighten the bolts to a torque of 42
± 5 lb.ft. (58 ±7 N-m).
A WARNING

until the rod is in position. 8 9 10
8. If necessary, start the engine to increase the pres

sure in the air system. Stop the engine.
NOTE: Shop air pressure of 70 psi (4.9 kg/cm2) or (480

kPa) can be used to activate the parking brake chamber.
9. Pull the emergency brake control valve (found on

the dash) to push the rod into position. Install the
pin and cotter pin to hold rod end (9) to camshaft
assembly (5).
10. Put intermediate drive shaft (10) in position and

install the bolts to hold it. Tighten the bolts to a
torque of 45 ± 5 lb.ft. (60 ± 7 N-m) with
hardened washers.
1 1. Fill the transmission with oil to the correct level.

Put clean grease in the universal joint and inter
mediate drive shaft.
end by:
a) install steering control valve
b) make an adjustment of the parking brake (see
ADJUSTMENT in TESTING AND AD
JUSTING)
30
STEERING WHEEL, STEERING COLUMN

REMOVE STEERING WHEEL 4309-11
Tools Needed A
8B7560 Step Plate 1
8B7550 Leg 2
8B7551 Bearing Puller Attachment 1
1. Remove the cover from the steering wheel.
2. Remove the nut that holds the steering wheel to

the shaft.
3. Move the steering column to install tooling (A)

and remove the steering wheel from the shaft.
INSTALL STEERING WHEEL 4309-12
1. Put the steering wheel in position on the shaft.
2. Install nut (1) to hold the steering wheel to the

shaft. Tighten the nut to a torque of 42 ± 3 lb.ft.
(58 ± 4 N-m).
3. Put a layer of 5P960 Multipurpose Type Grease

on nut (1).
4. Install the gasket and cover on the steering

wheel.
REMOVE STEERING COLUMN 4310-11
1. Remove four bolts (1) and steering column

positioner (2) from steering column (4).
2. Remove the ring from one end of shaft (3) and

remove the shaft from the other side of the steer
ing column. 3
3. Remove steering column (4) from the cover as

sembly and steering metering unit.
31

STEERING COLUMN
INSTALL STEERING
COLUMN 4310-12
1. Put steering column (2) in position on the cover
assembly. Make sure the splines of the steering
shaft engage correctly in steering metering unit
( 1 ).
2. Install shaft (4) and the rings that hold it in
position.
3. Install steering column positioner (3) and the
bolts that hold it and hand metering unit (1 ) in
position.
DISASSEMBLE STEERING
COLUMN 4310-15
Tools Needed A B C
2F5131 Wrench 1
1P510 Driver Group 1
9S9155 Spacer 1
8H663 Bearing Puller Attachment 1
start by:
a) remove steering wheel
b) remove steering column
1. Remove nut (1) from tube assembly (3) with tool

(A).
2. Remove the seal from nut (1) with tool group (B)
as shown.
3. Remove shaft (2) from tube assembly (3). Re

move the rings from shaft (2 ) that hold bearing
(4) in position.
A53930X1
32

STEERING COLUMN
4. Use a press and tooling (C) to remove the shaft
from bearing (4).
5. Remove tube assembly (3) from cover assembly

(5).
6. Remove the bushing from tube assembly (3) with

tool group (B).
7. Remove the two bearings from cover assembly

(5) with tool group (B).
8. If necessary, disassemble the steering column

positioner as follows:
a) Turn knob (8 ) counterclockwise to remove it
from pin assembly (6 ).
b) Remove pin assembly (6 ), the spring and
washer from housing (7).
33

STEERING COLUMN
ASSEMBLE STEERING COLUMN 4310-16
Tools Needed A B
2F5131 Wrench 1
1. Assemble the steering column positioner as fol

lows:
a) If necessary, make a replacement of the pin in
pin assembly (1). Make sure the pin is ex
tended evenly from both sides of pin assem
bly (1 ).
b) Install washer (2) and spring (3) on pin as
sembly (1 ).
c) Install pin assembly (1) in housing (4) and
install knob (5) in the end of pin assembly (1)
to hold it in the housing.
2. Use tool group (A) and install the bushing in tube

assembly (6 ) until the bushing is even with the
bottom of the tube assembly.
3. Use tool group (A) and install the bearings in

each side of cover assembly (7) until the bearings
are even with the outside surfaces of the cover
assembly.
4. Put tube assembly (6 ) in position in cover assem

bly (7). 5
5. Install bearing (8 ) on shaft (9). Install the rings

on each side of bearing (8 ) to hold it in position
on shaft (9).
A53930X2
34

STEERING COLUMN, STEERING METERING UNIT

6. Use tool group (A) to install the lip type seal in
nut (10). Make sure the lip of the seal is toward
the outside as shown.
7. Fill the bearing on shaft (9) with 5P960 Mul

tipurpose Type Grease and install the shaft in
tube assembly (6 ).
8. Put a layer of 5P960 Multipurpose Grease on the

lip of the seal in nut (10 ) and install the nut on
tube assembly (6 ) and tighten it with tool (B).
end by:
a) install steering column
b) install steering wheel A53942X1
REMOVE AND INSTALL STEERING

METERING UNIT 4312-10
start by:
a) remove steering column
1. Disconnect the four hydraulic lines (2) from hand

metering unit (1 ).
A53940X 1
2. Remove steering metering unit (1).
3. Put steering metering unit (1) in position and

connect the four hydraulic lines to it.
end by:
a) install steering column
35

STEERING METERING UNIT

DISASSEMBLE STEERING METERING
UNIT 4312-15
start by:
a) remove steering metering unit
l. Remove cap (1) from the housing.

A53944X1
2. Remove gear set (2) and spacer (3) from the

housing.
3. Remove drive (5) and plate (4) from housing (6 ).
5B1
A53945X1
NOTE:If housing (6 ), sleeve (7) and the spool have
damage or wear, these parts can not be ordered sepa
rately.
4. Remove sleeve (7) from housing (6 ).
5. Remove pin (10) and remove spool (9) from

sleeve (7). Remove six springs (8 ) from spool
(9).
36


6. Remove race (13), bearing (12) and race (11)
from housing (6 ).
7. Remove plate (14) from housing (6 ).
8. Remove O-ring seal (16) and bushing (15) from

plate (14). 9
9. Remove seals (17) and (18) from plate (14).
10. Remove plug (19), seat (20), ball (21) and spring
(22) from housing (6). *5 52 7 9 x1
37


ASSEMBLE STEERING METERING
UNIT 4312-16
Tools Needed A
CAUTION
Make sure all of the parts of the hand metering
unit are clean and free of dirt and foreign mate
rial. Put clean hydraulic oil on all of the parts.
1. Install spring (4), ball (3), seat (2) and plug (1) in
housing (5).
plate (6 ) with the lip of the seal toward the outside
as shown.
3. Install seal (8 ). bushing (7) and the O-ring seal in
plate (6 ). Make sure the open end of bushing (7)
is up when installed.
4. Put plate (6 ) in position on housing (5) and install
the bolts to hold it. Tighten the bolts to a torque of
250 lb.in. (28.3 N-m).
45587X2
5. Install race (11), bearing (10) and race (9) in

housing (5). Make sure that the bearing is be
tween the races.
6. Install six springs (14) in spool (12) with three

springs on each side. Make sure the curves of the
springs are in contact and in the center of the
spool. The notched side of the spring ends must
be up.
7. Install sleeve (13) over spool (12) so the notch

(slot) in the bottom of sleeve (13) engages with
the ends of springs (14). Install the pin that holds
the sleeve and spool together.
38


8. Install sleeve (13) in housing (5).
9. Put plate (16) in position on housing (5).
NOTE: The plate will fit on the housing one way only.
A55286X1
10. Install drive (15) in housing (5). Make sure the

notch (slot) in drive (15) is engaged with the pin
that holds the sleeve and spool together.
11. Install spacer (18) and gear set (17).
NOTE: Make sure the gear of gear set (17) is in align

ment with pin (19) as shown. Pin (19) is the pin that
holds the sleeve and spool together.
12. Put cap (20) in position and install the bolts to

hold it. Tighten the bolts to a torque of 250 lb.in.
(28.3 N-m).
end by:
a) install steering metering unit
39

STEERING CONTROL VALVE

REMOVE AND INSTALL STEERING
CONTROL VALVE 4307-10
A WARNING
Stop the engine, lower the bucket to the

ground, move the control levers backward and
forward to release the pressure in the hydraulic
system. Slowly loosen the cap to release any
pressure in the hydraulic tank. Let the hyd
raulic oil become cool before any lines are dis
connected in the hydraulic system. Put blocks
in front and behind the wheels.
2. Drain the oil from the hydraulic tank. The capac

ity of the system is:
920-17.5 U.S. gal. (6 6 litre)
930-19.5 U.S. gal. (74 litre)
3. Disconnect hose assemblies (1) and (3) from tube
assemblies (2) and (4).
machine.
5. Disconnect tube assembly (5) from tube assem
bly (6 ). Disconnect tube assemblies (6 ) and (7)
from the control valve.
6. Disconnect the hose assembly and two tube as
semblies from the back of the control valve.
7. Remove the three bolts that hold the control valve
to the frame and remove the valve. The weight of
the valve is 55 lb. (25 kg).
8 . Put the control valve in position and install the
bolts to hold it.
9. Put clean hydraulic oil on the O-ring seals for the
tube assemblies.
10. Connect tube assemblies (6 ) and (7) to the control
valve. Connect tube assembly (5) to tube assem
bly (6 ).
11. Connect the two tube assemblies and hose as
sembly to the back of the control valve.
12. Install tube assemblies (2) and (4) on the machine
and connect them to the control valve.
13. Connect hose assemblies (1) and (3) to tube as
semblies (2) and (4).
14. Fill the hydraulic system with oil to the correct
level.
40


DISASSEMBLE STEERING CONTROL
VALVE 4307-15
start by:
a) remove steering control valve
1. Remove the right turn neutralizer valve (1) and

the O-ring seals from the main valve body.
A WARNING
Spring (4) is under tension and can push seat

(6) out of the valve body with force. Use care
when valve (1) is removed so seat (6) does not
come out of the valve body and cause bodily
injury. 2 3
2. Remove seat (6 ), valve (5), spring (4), shims (3)

and plug (2) from the valve body. Remove the
O-ring seals from plug (2), seat (6 ) and the valve
body.
3. Remove plug assembly (10), the O-ring seal,

spring and ball from the neutralizer valve body.
A55493X t
4. Remove plug (9) and the O-ring seal.
5. Remove boot (8 ) from the valve stem. Remove

plug (7), the O-ring seal and spring. Remove the
bolt, lockwasher and washer that hold the valve
stem. Remove the valve stem from the
neutralizer valve body.
f
6. Remove seal (11), the five plugs (12) and O-ring A55494X1
seals from the neutralizer valve body.
41


7. Remove spring (15) and valve (13) from the main
/
valve body. Remove spring (15) and the shims f•
from valve (13).
8. Remove valve stem assembly (16) and pin (14)

from the main valve body.
9. To disassemble valve stem assembly (16), re

move the bolt, lockwasher, washer, retainer
(19), spring (18), spacer (17), the retainer and
shims from valve stem (2 0 ).
10. Remove left turn neutralizer valve (21) and the

O-ring seals from the main valve body.
11. Remove spacer (22) from the main valve body.

13. Remove boot (23) from the valve stem. Remove

plug (24), the O-ring seal and spring. Remove the
bolt, lockwasher and washer that hold the valve
stem. Remove the valve stem from the
A55489X!
42


14. Remove the lip type seal for the valve stem from
the neutralizer valve body.

16. Remove plugs (26) and (28), fitting (29) and the
O-ring seals from the neutralizer valve body.
17. Remove selector valve (30) and the O-ring seals

from the main valve body.
18. Remove plug (33), the O-ring seal, spring and

valve stem. Remove the plug and O-ring seal
from the other end of the selector valve body.
19. Remove fittings (31), plugs (32) and the O-ring

seals from the selector valve body.
20. Remove five plugs (34) and the O-ring seals from
the main valve body.
21. Remove plug (35), the O-ring seal, seat, ball and
A55499X1
seat. Remove the O-ring seals from the seats.
43


ASSEMBLE STEERING CONTROL
VALVE 4307-16
Tools Needed A
CAUTION
All parts must be kept clean. Use paper free of
lint and clean solvent to clean the parts. Put
clean hydraulic oil on all of the parts before
they are assembled.
1. Install the five plugs (2) and O-ring seals in the

main valve body.
2. Install the O-ring seal on the seat for ball (1) and
install it in the main valve body. Put the O-ring
seal on seat (3). Install ball (1), seat (3), the
O-ring seal and plug (4) in the main valve body.
3. Install the five plugs (10), plug (5), fittings (6 )

and the O-ring seals in the selector valve body.
4. Install valve stem (7), spring (8 ), the O-ring seal

and plug (9) in the selector valve body as shown.
5. Install the O-ring seals in selector valve (11) and

put it in position on the main valve body. Tighten
the bolts that hold the selector valve.
6. Install the O-ring seal and plug (12) in the left

turn neutralizer valve body. Tighten the plug to a
torque of 42 ± 4 lb.ft. (58 ± 5 N-m). 7
7. Use tool group (A) and install the seal in the left
turn neutralizer valve body. Make sure the lip of
the seal is toward the inside as shown.
44


8. Install fitting (13), the five plugs (20) and the
O-ring seals in the neutralizer valve body.
9. Install the ball, spring, the O-ring seal and plug

assembly (19). Tighten the plug assembly to a
torque of 19 ± 2 lb.ft. (25 ± 3 N-m).
10. Install valve stem (14), washer (22), lockwasher

(21) and bolt (16). Tighten bolt (16) in the end of
valve stem (14) to a torque of 10 ± 2 lb.ft. (14 ±
3 N-m).
11. Install spring (17), the O-ring seal and plug (18).
Tighten the plug to a torque of 75 ± 6 lb.ft. (100
± 8 N-m).
12. Install boot (15) for the valve stem on the

13. Install the O-ring seal and plug (26). Install ball
(25), spring (24) and plug assembly (23). Tighten
the plug assembly to a torque of 25 ± 3 lb.ft. (35
± 4 N-m).
14. Install spacer (27) in the main valve body. Install

the O-ring seals in the left turn neutralizer valve
(28). Put neutralizer valve (28) in position on the
main valve body and install the bolts to hold it.
15. Install shims (36), retainer (35), spacer (34),

spring (33), retainer (32), washer (31),
lockwasher (30) and bolt (29) on valve stem (37).
Tighten bolt (29) to a torque of 15 ± 2 lb.ft. (20
± 3 N-m).
16. Install pin (38), valve spool (39), shims (40),

spring (41) and valve stem assembly (42) in the
main valve body. A55672X1
45


17. Use tool group (A) and install the lip type seal for
the valve stem in the right turn neutralizer valve
body. Make sure the lip of the seal is toward the
inside as shown.
18. Install valve stem (44), washer (48), lockwasher

(49) and bolt (45). Tighten bolt (45) in the end of
valve stem (44) to a torque of 10 ± 2 lb.ft. (14 ±
3 N-m).
19. Install spring (46), the O-ring seal and plug (47).
Install boot (43) for valve stem (44) on the
20. Install the five plugs (52) and the O-ring seals in
the neutralizer valve body. Tighten the plugs to a
torqueof3 + 2or - 1 lb.ft. (4 + 3 or - 1 N-m).
21. Install the O-ring seals on seat (55) and plug (50).
Install spring (53), valve (54), seat (55), shims
(51) and plug (50) in the neutralizer valve body as
shown.
22. Install the O-ring seals in the right turn

neutralizer valve (56). Put neutralizer valve (56)
in position on the main valve body and tighten the
bolts to hold it.
23. See Hydraulic Steering System in TESTING

AND ADJUSTINNG for shim adjustment.
end by:
a) install steering control valve A55677X 1
46

STEERING CYLINDERS
REMOVE STEERING CYLINDERS 4303-11
1. Turn the machine all of the way to the left to

remove the right steering cylinder. Turn the
machine all of the way to the right to remove the
left steering cylinder. Put blocks in front and
behind the wheels.
A WARNING

pressure in the hydraulic tank. Let the hy
draulic oil become cool before any lines are
disconnected in the hydraulic system.
2. Remove bolt (2) from the bottom of the rear

cylinder pin.
3. Disconnect hose assembly (1 ) from the rear of the

steering cylinder.
4. Remove fender (3) and access covers (4) and (5)

from the machine.
AS 18 9SX1
5. Remove bolt (7). Remove pin (6 ) from the top of

the frame. 6
6. Disconnect the lower end of hose assembly (9)

from the tube assembly. Remove hose assembly
(9) and fitting (8 ) from the front of the steering
cylinder.
47

STEERING CYLINDERS
7. Remove bolt (11), the lockwasher and washer.
Remove the pin, that holds the cylinder rod to the
frame, from the top of the frame.
A WARMING
Use care when the steering cylinder is removed

because of its weight. A hoist can not be fas
tened to the cylinder until it is removed.
8. Remove steering cylinder (10) from the front of

the frame. The weight of the cylinder is 50 lb. (23
kg).
9. Remove the washers for the cylinder rod from the

frame.
INSTALL STEERING CYLINDERS 4303-12
NOTE: Make sure the cylinder rod is extended before

the steering cylinder is installed.
I. Put steering cylinder (1) in position in the frame.
2. Install washers (2) on both sides of the rod end as

needed to make the steering cylinder level.
3. Install pin (3) to hold the cylinder rod. Install the

bolt, lockwasher and washer that hold the pin. 4
4. Install pin (4). Install the bolt and lockwasher to

hold clip (5) and the grease line for pin (4).
48

STEERING CYLINDERS
5. Install the washer, lockwasher and bolt (7) to
hold the rear cylinder pin.
6. Put clean hydraulic oil on the O-ring seal and

connect hose assembly (6 ) to the steering cylin
der.
7. Install fitting (8 ) and hose assembly (9) to the

steering cylinder.

connect the lower end of hose assembly (9) to the
tube assembly.
9. Install access covers (10) and (11) and the fender

on the machine.
10. Put dean grease in the cylinder pins.
11. Start the engine and turn the machine all of the
way in both directions several times. Stop the
engine and fill the hydraulic tank to the correct
level.
DISASSEMBLE STEERING
CYLINDERS 4303-15
Tools Needed A B C
7F9540 Hydraulic Puller 1
9S5559 Stud 1
7M7238 Sleeve (part of
7M7236 Adapter Group) 1
1P543 Nut 1
1P1831 Bearing Puller Adapter 1
5P3100 Pump Group 1 1
1P1784 Hydraulic Cylinder
Repair Stand 1
1P850 Torque Multiplier 1
1P851 Spline Adapter 1
1P852 Male Adapter 1
5P3588 Adapter 1
8H8539 Socket 1
start by:
remove steering cylinders 1
1. Remove seals (1) from each side of the rod as

sembly and cylinder assembly.
49

STEERING CYLINDERS
2. Remove the bearings from the rod assembly and
cylinder assembly with tooling (A).
3. Put the cylinder in position on tooling (B). Install

support (3) under the rod and fasten strap (2)
around the rod to hold it in position.
4. Put a mark on the head and cylinder assembly for

correct alignment at assembly. Remove four
bolts (4).
5. Pull the cylinder away from the rod and head with
tooling (B).
6. Use tooling (C) to remove the nut that holds

piston (5) on the rod. Remove piston (5) and the
washer from the rod. A51905XH
iUSa
7. Remove seal assembly (7) and ring (6 ) from the

piston.
8. Remove head (8 ) from the rod.
9. Remove the back-up ring and O-ring seal (9)

from head (8 ).
50

STEERING CYLINDERS
10. Remove three seals (10) from head (8 ).
ASSEMBLE STEERING CYLINDERS 4303-16
Tools Needed A B O D E F G
5P2980 Seal Installer 1
5P3537 Seal Guide 1
4S9181 Seal Expander 1
Repair Stand 1
5P3588 Adapter 1
8H8539 Socket 1
9S5559 Stud 1
7M7238 Sleeve 1
1P543 Nut 1
1. Use tool (A) to install seal (4) in head (1).
2. Install seal (3) in the head with the lip of the seal
toward seal (4).
3. Use tool group (B) to install seal (2) in the head

with the lip of the seal toward the outside.
4. Install O-ring seal (6 ) and back-up ring (5) in the

head as shown.
5. Put the cylinder assembly and rod on tooling (E).
6. Install tool (C) on the rod. Put clean hydraulic oil

on the lips of the seals in the head. Push the head
on the rod. Remove tool (C) from the rod. 7
7. Use tool (D) to cause expansion of the plastic seal A45936X!
(7) of the piston seal assembly.
51

STEERING CYLINDERS
8. Install the rubber expansion ring in the groove of
piston (10) and install plastic seal (7) over the
rubber expansion ring.
9. Install seal ring (9) on piston (10).
10. Install washer (8 ) and piston (10) on the rod as

shown.
11. Use tooling (F) to tighten the nut that holds the
piston on the rod. Tighten the nut to a torque of
650 ± 65 lb.ft. (880"± 90 N-m).
12. Put clean hydraulic oil on the seal and ring on the
piston and on the back-up ring and O-ring seal on
the head.
13. Make an alignment of the marks on the head and

cylinder assembly. Slowly push the cylinder as
sembly on to the piston and head with tooling (E).
Be careful not to damage the O-ring seal and the
back-up ring on the head.
14. Make sure the rod is fully extended from the

cylinder assembly and tighten the bolts that hold
head (1 ).
15. Remove the cylinder assembly from tooling (E).
16. Install the bearings in the cylinder assembly and

rod assembly with tooling (G). Install the bear
ings until they are in the center of their bore.
17. Use tool group (B) to install the seals in the

cylinder and rod assemblies until the seals make
contact with the bearings.
NOTE: The lip of the seals must be toward the outside

as shown.
end by:
a) install steering cylinders
52

BUCKET
REMOVE BUCKET 6101-11
l. Make sure the bucket is flat on the ground.
2. Stop the engine and move the hydraulic control

levers backward and forward to release the pres
sure in the hydraulic system.
3. Remove bolts (1) and (2) from each side of the

bucket.
4. Remove pins (3) and washers (used for the lower

bucket pins) from both sides of the bucket.
5. Start the engine and move the machine away

from the bucket. The weight of the bucket is:
920-1650 lb. (743 kg)
930-1875 lb. (849 kg)
INSTALL BUCKET 6101-12
1. Move the machine up to the bucket and put the

lift arms in position in the lower bucket hinge
bosses.
2. Put pins (2) in position in the lower bucket hinge

boss with hole in the pin in alignment with the
hole in the the boss.
3. Install the washers on each side of lift arms (1).
Push pins (2) into position.
4. Install bolts (4) and the nuts to hold the lower pins
in position.
5. Put the link assemblies in position in the upper

bucket hinge bosses and install pins (3). Make
sure the holes in the pins are in alignment with the
holes in the bosses before the pins are installed all
of the way.
6. Install the bolts and nuts to hold the upper pins in

position. 7
7. Put clean grease in the four bucket pins.
53

BUCKET POSITIONER
REMOVE BUCKET POSITIONER 5112-11
NOTE: The bucket is in the "RAISED” position for

better photo illustration of the removal and installation
of the bucket positioner.
1. Remove ring (1) that holds the lower end of the

bucket positioner.
2. Remove the two bolts (3) and remove bucket

positioner (2 ) from the machine.
3. Remove bearing (4) from the tilt cylinder pin.
INSTALL BUCKET POSITIONER 5112-12
1. Install bearing (1) on the tilt cylinder pin.
2. Put bucket positioner (2) on the tilt cylinder and

install the two bolts to hold it in position.
3. Install the ring on the tilt cylinder pin.
4. Make an adjustment of the bucket positioner. See

BUCKET POSITIONER in TESTING AND
ADJUSTING.
54

BUCKET POSITIONER
DISASSEMBLE BUCKET
POSITIONER 5112-15
Tools Needed
1P1857 Pliers
start by:
a) remove bucket positioner
A51920X1
l. Remove bolts (2), cam (l) and the two clamps

from the upper end of the tube assembly.
2. Remove the bolt and support (3) from the shaft.
3. Use tool (A) and remove the ring that holds cover
(4) in the lower end of the tube assembly. Re
move cover (4).
A51926X1
4. Remove shaft (5) from the lower end of the tube

assembly.
5. Remove nut (6 ), the washer and bearing (7) from

shaft (5).
6. Remove ring (8 ), seal (9), the bearing and washer

from the upper end of the tube assembly.
A51929X1
55

BUCKET POSITIONER
ASSEMBLE BUCKET
POSITIONER 5112-16
Tools Needed A B
1P1857 Pliers 1
1. Install washer (4) and bearing (3) in the upper end

of tube assembly (5).
2. Use tool group (B) to install seal (2) in tube

assembly (5) with the lip of the seal toward the
outside. Install ring (1).
3. Install bearing (8 ), washer (7) and nut (6 ) on shaft

(9).
4. Put clean engine oil on bearings (3) and (8 ).

Install shaft (9) in tube assembly (5). A51931X1
5. Install cover (11) in the lower end of the tube

assembly. Use tool (B) to install ring (10) in the
tube assembly.
6. Install support (13) on the shaft.
7. Install cam (12) and the clamps on the tube as

sembly.
end by:
A54400X1
a) install bucket positioner
56

BUCKET POSITIONER MASTER CYLINDER

REMOVE BUCKET POSITIONER
MASTER CYLINDER 5112-11
1. Disconnect line (2) from master cylinder (1).

2. Remove the two bolts and remove master cylin
der (1 ) from the tilt cylinder.
INSTALL BUCKET POSITIONER

Tools Needed A
8S7630 Stand 1
8S7641 Tube 1
8S8048 Saddle 1
8S7615 Pin 1
1. Put master cylinder (1) in position on the tilt

cylinder and install the two bolts to hold it.
2. Connect the oil line to master cylinder (1).
3. Start the engine and lift the bucket until the tilt
cylinder is level. Stop the engine and put tooling
(A) under the lift arm for support. Move the
control lever to lower the weight of the lift arms
and bucket on tooling (A).
4. Fill the master cylinder with brake fluid. Make
sure the cap is installed on the master cylinder.
5. Fasten a hose to the bleed valve on the slave
cylinder (found under the operator’s seat). Put
the loose end of the hose in a reservoir (container)
of brake fluid until it is below the surface of the
fluid.
6 . Hold the tilt control lever in the ‘‘TILT BACK"
position so the slave cylinder push rod does not
move.
7. Activate the master cylinder several times and
hold the rod and piston all of the way in the
master cylinder bore.
8. Open the bleed valve (2) on the slave cylinder.
Close the bleed valve when the pressure is not
high enough to push brake fluid out.
9. Do Steps 1 through 5 until there are no air bub
bles in the brake fluid that comes out of the bleed
valve. Fill the master cylinder with brake fluid.
10. Remove tooling (A) from under the lift arms and
lower the bucket to the ground.
11. Make an adjustment of the bucket positioner. See
BUCKET POSITIONER in TESTING AND
ADJUSTING.
57

LIFT KICKOUT MASTER CYLINDER, BUCKET POSITIONER

OR LIFT KICKOUT MASTER CYLINDER
REMOVE AND INSTALL KICKOUT
1. Remove the four nuts and lockwashers that hold
cover assembly (2 ) to the lower right side of the
front frame.
2. Remove cover assembly (2) and master cylinder
(1) from the frame. Disconnect oil line (3) from
the master cylinder.
3. Connect oil line (3) to master cylinder (1).
4. Fill the master cylinder with brake fluid. Make
sure the cap is installed on the master cylinder.
5. Fasten a hose to the bleed valve on the slave
cylinder (found under the operator’s seat). Put
the loose end of the hose in a reservoir (container)
of brake fluid until it is below the surface of the
fluid.
6 . Hold the lift control lever in the “RAISE” posi
tion so the slave cylinder push rod does not move.
7. Activate the master cylinder several times and
hold the rod and piston all of the way in the
master cylinder bore.
8 . Open the bleed valve (4) on the slave cylinder.
Close the bleed valve when the pressure is not
high enough to push brake fluid out.
9. Do Steps 1 through 5 until there are no air bub
bles in the brake fluid that comes out of the bleed
valve. Fill the master cylinder with brake fluid.
10. Put master cylinder (1) and cover assembly (2) in
position. Install the four nuts and lockwashers
that hold the cover assembly.
DISASSEMBLE BUCKET POSITIONER

OR LIFT KICKOUT MASTER
CYLINDER 5112 & 5109-15
Tools Needed A B
1P1855 Pliers 1
start by:
a) remove bucket positioner or lift kickout mas
ter cylinder A54406X1
1. Remove cotter pin and pin (2). Use tool (A) to

remove the ring that holds lever assembly (4) in
position. Remove lever assembly (4) and the lock
from bracket assembly (1 ).
2. Remove the nut. washer and roller (3) from lever
assembly (4).
58

BUCKET POSITIONER OR LIFT KICKOUT MASTER CYLINDER

ASSEMBLE BUCKET POSITIONER
OR LIFT KICKOUT MASTER
CYLINDER 5112 & 5109-16
Tools Needed A B
1P1855 Pliers 1
NOTE: When the hydraulic system is serviced use

caution to prevent introduction of foreign material into
the brake fluid. Damaged or worn rubber parts are an
indication of other fluids in the system. Flush and clean
the system with denatured alcohol or clean brake fluid.
master cylinder at assembly.
2. Inspect the bore in the master cylinder. Use a
brake cylinder hone to remove any rough areas or
corrosion in the master cylinder bore. If the cy
linder bore has deep scratches a replacement of
the master cylinder is needed.
3. Make sure the master cylinder bore is clean.
Install seat assembly (2) with the seal and the end
of the seat that has the larger outside diameter
toward the rear of cylinder assembly (1 ).
4. Install spring and retainer assembly (3) as shown.
Make sure the retainer is installed on the small
end of the spring. Install cup (4) with the open
end toward spring (3).
5. Install seal (6 ) in the groove of piston assembly
(5) and install the piston assembly as shown.
Install plate (7) and lockwire (8 ).
CAUTION
Make sure lockwire (8) is fitted correctly in the
groove of cylinder assembly (1) and piston as
sembly (5) moves back against plate (7). 6 7 8 9 10
6. Install boot (9) on cylinder assembly (1). Install

rod assembly (10 ) in the cylinder assembly and
boot.
7. Install the gasket and adapter (12) in cylinder
assembly (1). Tighten adapter (12) to a torque of
150 lb.ft. (205 N-m).
8. Install the diaphram and cover (11).
9. Put bracket assembly (13) in position and install
the two bolts that hold it to cylinder assembly (1 ).
10. Install the bearing in lever assembly (14) with
tool group (A) until the bearing is in the center of A54413X1
its bore.
60

VEHICLE SYSTEMS
BUCKET POSITIONER OR LIFT KICKOUT MASTER CYLINDER,

BUCKET POSITIONER AND LIFT KICKOUT SLAVE CYLINDERS
11. Install roller (15) and the nut on the lever assem
bly.
12. Put the lever assembly in position on the bracket

assembly.
13. Put 5P960 Multipurpose Type Grease on the pin

that holds the lever assembly to rod assembly
(10). Install the pin and cotter pin.
14. Install the lock and use tool (B) to install the ring *54414x1
that holds the lever assembly to the bracket as
sembly.
end by:
a) install bucket positioner or lift kickout master
cylinder
REMOVE AND INSTALL BUCKET

POSITIONER AND LIFT KICKOUT
SLAVE CYLINDERS 5112 & 5109-10
1. Lift the operator’s seat.

2. Disconnect oil line (4) from lift kickout slave
cylinder (1). Disconnect oil line (3) from bucket
positioner slave cylinder (2 ).
3. Remove the bolts that hold slave cylinders (1)
and (2 ) and remove them from the machine.
4. Put slave cylinders (1) and (2) in position on the
back of the hydraulic tank. Install the bolts that
hold the cylinders.
5. Connect oil lines (3) and (4) to slave cylinders (2)
and (1 ).
6. Remove (bleed) the air from the bucket
positioner and lift kickout systems. See Install
Bucket Positioner Master Cylinder tor this pro
cedure.
7. Make an adjustment to the slave cylinders. See
Bucket Positioner Indicator and Positioner also
Lift Kickout in TESTING AND ADJUSTING.
61

BUCKET POSITIONER OR LIFT KICKOUT SLAVE CYLINDER

DISASSEMBLE BUCKET POSITIONER
OR LIFT KICKOUT SLAVE
CYLINDER 5112 OR 5109-15
Tools Needed A
1P1857 Pliers 1
start by:
a) remove bucket positioner or lift kickout slave A55659X1
cylinder
1. Remove boot (1) from the cylinder.
2. Remove ring (3) from the cylinder with tool (A).
A55660X1
3. Remove push rod and spring assembly (2) from

the cylinder. Remove the piston assembly from
the cylinder.
NOTE: The individual parts of the push rod and spring

assembly can not be ordered separately.
4. The push rod and spring assembly can be disas

sembled to clean and inspect as follows:
a) Push spring (7) and retainer (8 ) toward bolt
(4). Remove the rings that hold retainer (8 ) in
position.
b) Remove retainer (8 ), spring (7) and seat (6 )
from rod (5).
c) Remove bolt (4) and the nut from rod (5).
NOTE: A cylinder repair kit is available. The kit in

cludes a piston, cup, cup retainer, two retainer rings,
lockwire and a boot. When the slave cylinder is disas
sembled for service, always install a repair kit.
62

VEHICLE SYSTEMS
BUCKET POSITIONER OR LIFT KICKOUT SLAVE CYLINDER

ASSEMBLE BUCKET POSITIONER
OR LIFT KICKOUT SLAVE
CYLINDER 5112 OR 5109-16
Tools Needed A
1P1857 Pliers 1
NOTE: When the hydraulic system is serviced, use

caution to keep foreign material out of the brake fluid.
Damaged or worn rubber parts are an indication of other
fluids in the system. Flush and clean the system with
denatured alcohol or clean brake fluid.

cylinder at assembly.
2. Inspect the bore in the cylinder. Use a brake

cylinder hone to remove any rough areas or cor
rosion in the cylinder bore. If the cylinder bore
has deep scratches a replacement of the cylinder
is needed.
3. Install the nut and bolt (6 ) in the end of rod (5).
4. Install seat (4), spring (3) and retainer (2) on rod

(5).
5. Push retainer (2) toward bolt (6 ) and install rings

(1 ) to hold the retainer in position.
6. Install the cup on piston assembly (8 ).
7. Make sure the cylinder bore is clean and install

piston assembly (8 ), the push rod and spring
assembly (10) in cylinder (7). 8 9
8. Use tool (A) to install ring (9) that holds the push
rod and spring assembly in position.
9. Install boot (11) on cylinder (7).
end by:
a) install bucket positioner or lift kickout slave
cylinder
63

LIFT CYLINDERS
REMOVE LIFT CYLINDERS 5102-11
Tools Needed A B C
8S7630 Stand 1
8S7641 Tube 1
8S8048 Saddle 1
8S7615 Pin 1
1P7421 Tap (1 ”-14 NF) 1
5F7693 Spacer (part of
5F7334 Spacer Group) 1
1B4209 Nut (part of
8B7548 Puller Assembly) 1
5F7366 Stud (part of
8B7548 Puller Assembly) 1
5P3100 Pump Group 1
l. Lift the bucket and put tooling (A) in position

under the lift arm for support. Move the control
lever and lower the weight of the lift arms and
bucket on tooling (A) as shown.
A WARNING
VIEW FROM UNDER MACHINE
Stop the engine, move all control levers back
ward and forward to release the pressure in the
hydraulic system. Slowly loosen the cap to re
lease any pressure in the hydraulic tank. Let
the hydraulic oil become cool before any lines
are disconnected in the hydraulic system. 2 3 4 5 6
2. Disconnect hose assemblies (1) and (2) from

inside the front frame.
3. Remove bar (3) that holds the rod pin.
4. Fasten a hoist to the lift cylinder.

CO
5. If necessary use tool (B) to clean the threads of

the rod pin.
6. Install tool (C) and remove the rod pin from

inside of the lift arm.
64

LIFT CYLINDERS
7. Remove bar (4) that holds the cylinder pin in the
frame.
8. If necessary use tool (B) to clean the threads in

the cylinder pin (5). Use tool (C) and remove the
cylinder pin.
9. Remove the lift cylinder. The weight of the cy

linder is 168 lb. (76 kg).
INSTALL LIFT CYLINDERS 5102-12
Tools Needed A
8S7630 Stand 1
8S7641 Tube 1
8S8048 Saddle 1
8S7615 Pin 1
1. Pull the rod (1) almost all of the way out of the
cylinder.
2. Fasten a hoist to the lift cylinder and put it in
3. Install pins (2) and (3) to hold the cylinder in

position. Install the bars to hold pins (2) and (3).
4. Put clean hydraulic oil on the O-ring seals and

connect hose assemblies (4) and (5) to the lift
cylinder.
5. Put clean grease in the cylinder pins.
6. Remove tooling (A) from under the lift arms and

lower the bucket to the ground. 7

level.
V
A54421X1
*1*
65

LIFT CYLINDERS
DISASSEMBLE LIFT sc
CYLINDERS 5102-15
Tools Needed A B C D
Repair Stand 1
5P3100 Pump Group 1 1 1
7F9540 Hydraulic Puller 1 1
9S5559 Stud 1 1
1P543 Nut 1 1
5F7334 Spacer Group) 1 1
1P1833 Adapter 1
1P1834 Adapter 1
5S6077 Socket 1
start by:
a) remove lift cylinders
1. Fasten a hoist to the lift cylinder and put it in
position on tooling (A).
cylinder assembly.
3. Remove seals (3) from each side of the rod as

sembly.
4. Use tooling (B) to pull the bearing out of the rod

assembly.
5. Remove seals (4) from each side of the cylinder

assembly. 6
6. Use tooling (C) to pull the bearings and spacer

from the cylinder assembly.
66

LIFT CYLINDERS
7. Make sure support (6) is in position under the rod

and fasten strap (5) around the rod to hold it.

correct alignment at assembly. Remove four
bolts (7).
9. Pull the cylinder away from the rod and head with
tooling (A).
10. Use tooling (D) to remove the nut that holds

piston (8) on the rod. Remove piston (8) from the
rod.
11. Remove wear ring (9) and seal assembly (10)

from the piston.
12. Remove head (11) from the rod.

from head (11).
14. Remove three seals (13) from head (11).
67

LIFT CYLINDERS
ASSEMBLE LIFT CYLINDERS 5102-16
Tools Needed A B O D E F G H
5F2980 Seal Installer 1
1P765 Seal Guide 1
Repair Stand 1
5S6077 Socket 1
7F9540 Hydraulic Puller 1 1
9S5559 Stud 1 1
1P543 Nut 1 1
1P1834 Adapter 1
1P1833 Adapter 1
toward seal (4).

4. Install O-ring seal (6) and back-up ring (5) in the

head as shown.

on the rod. Remove tool (C) from the rod. 7
7. Use tool (D) to cause expansion of the plastic seal A45936X1

68

LIFT CYLINDERS

the piston and install plastic seal (7) over the
9. Install wear ring (9) on the piston. Install piston

(8) on the rod as shown.
1200 ± 120 lb.ft. (1620 ± 160 N-m).
11. Put clean hydraulic oil on the seal and wear ring
on the piston and on the back-up ring and O-ring
seal on the head.


head (1).
15. Use tooling (G) to pull a bearing in the cylinder

assembly bore until it is .312 in. (7.92 mm) from
the surface of the cylinder assembly.
16. Turn the cylinder assembly over and use tooling

(G) to pull the spacer and second bearing in the
cylinder assembly bore until the spacer makes
contact with the first bearing installed.
17. Use tooling (H) to pull the bearing into the rod
assembly until it is in the center of its bore. A54437X
69

LIFT CYLINDERS, TILT CYLINDERS

as shown.
install tube assemblies (10) and (11) on the cylin
der assembly.
end by:
a) install lift cylinders
REMOVE TILT CYLINDERS 5104-11
Tools Needed A B
1P7421 Tap (1 ”-14 NF) 1
9S5565 Sleeve Assembly 1
9S5559 Stud 1
1P543 Nut 1
5P3100 Pump Group 1
start by:
a) remove bucket positioner*
b) remove bucket positioner master cylinder*
*NOTE: These steps are needed for the right side only.
I. Lift the bucket until tooling (B) can be installed.
Install blocks or stands under the lift arms and
bucket for support.
A WARNING
Stop the engine and move all control levers
backward and forward to release the pressure
in the hydraulic system. Slowly loosen the cap
to release any pressure in the hydraulic tank.
Let the hydraulic oil become cool before any
lines are disconnected in the hydraulic system. 2 3 4 5 6
2. Fasten a hoist to the tilt cylinder.

3. If necessary use tool (A) and clean the threads in
the rod pin.
4. Remove the bolt that holds the rod pin. Install
tooling (B) and remove the rod pin.
NOTE: Tooling (B) can not be used on the right side.
5. Remove two bolts (2) that hold the upper tube
assembly (1) and the lower tube assembly to the
tilt cylinder.
6. Disconnect upper tube assembly (1) and the
lower tube assembly from the tilt cylinder. Move
the tube assemblies out of the way for removal of
the tilt cylinder.
70

TILT CYLINDERS
7. Disconnect the wire from headlight (4).
8. Remove bolt (3) and headlight (4) from the

frame.
9. If necessary use tool (A) and clean the threads of

the cylinder pin.
10. Install tooling (B) and remove the cylinder pin.

Remove the tilt cylinder. The weight of the tilt
cylinder is 110 lb. (49.5 kg).
INSTALL TILT CYLINDERS 5104-12
1. Fasten a hoist to the tilt cylinder and put it in

position in the machine.
2. Install cylinder pin (1) with the hole in the pin in

alignment with the hole in the frame.
3. Put the headlight in position and install the bolt

that holds it and the cylinder pin.
4. Put the rod in position and install rod pin (2) with
the hole in the pin in alignment with the hole in
the lever.
5. Install the bolt that holds the rod pin.
6. Put clean hydraulic oil on the O-ring seals. Con

nect the lower tube assembly and upper tube
assembly (3) to the tilt cylinder. Install the bolts
that hold the tube assembly clamps.
7. Put clean grease in the cylinder and rod pins.
8. Remove the blocks or stands from under the

bucket and lift arms. Lower the bucket to the
ground.

level.
end by:
a) install bucket positioner
b) install bucket positioner master cylinder
71

TILT CYLINDERS
DISASSEMBLE TILT
CYLINDERS 5104-15
Tools Needed A B C
Repair Stand 1
7M7238 Sleeve (part of
7M7236 Adapter Group) 1
5P2145 Adapter 1
9S5559 Stud 1
1P543 Nut 1
5S6077 Socket 1
start by:
a) remove tilt cylinders
1. Remove seals (1) from each side of the cylinder
and rod assemblies.
2. Use tooling (B) to pull the bearings from the
cylinder and rod assemblies.
3. Fasten a hoist and put the cylinder in position on
tooling (A). Install support (3) under the rod and
fasten strap (2) around the rod to hold it in posi
tion.
correct alignment at assembly. Remove bolts (4).
5. Pull the cylinder away from the head with tooling
(A).
6. Use tooling (C) to remove the nut that holds the
piston on the rod.
7. Remove piston (6) and head (5) from the rod.
72

TILT CYLINDERS
8. Remove wear ring (7) and seal assembly (8) from
piston (6).
CO
from head (5).
10. Remove three seals (10) from head (5).
ASSEMBLE TILT CYLINDERS 5104-16 1 2 3 4
Tools Needed A B O D E F G
5P2980 Seal Installer 1
5P320 Seal Guide 1
Repair Stand 1
5S6077 Socket 1
5P2145 Adapter 1
9S5559 Stud 1
1P543 Nut 1

toward seal (4).
4. Install O-ring seal (6) and back-up ring (5) in the
head as shown.
73

TILT CYLINDERS

on the rod. Remove tool (C) from the rod.
7. Use tool (D) to cause expansion of the plastic seal

A45936X1
8. Install wear ring (9) on piston (8).

piston (8) and install plastic seal (7) over the
10. Install piston (8) on the rod.
1200 ± 120 lb.ft. (1620 ± 160 N-m).
74

TILT CYLINDERS. LIFT ARMS

12. Put clean hydraulic oil on the seal and wear ring
on the piston and on the back-up ring and O-ring
seal on the head.
head (1).
16. Install the bearings in the cylinder assembly and
rod assembly with tooling (G). Install the bear
ings until they are in the center of their bore.
as shown.
end by:
a) install tilt cylinders
REMOVE LIFT ARMS 6119-11
Tools Needed A B C D E
1P7421 Tap (1 ”-14 NF) 1
7F9540 Hydraulic Puller 1 1 1
9S5565 Sleeve Assembly 1
9S5559 Stud 1 1
1P543 Nut 1 1
5P3100 Pump Group 1 1 1 1
5F7334 Spacer
Group) 1
1P4209 Nut (part of 8B7548
Puller Assembly) 1
5F7366 Stud (part of 8B7548
Puller Assembly) 1
5H9817 Hydraulic Puller
Assembly 1 1. Start the engine and extend the tilt cylinders until
9S5558 Stud 1 lever assemblies (1) are in the position shown.
9S5564 Sleeve Assembly 1 Stop the engine and fasten chains around lever
1P544 Nut 1 assemblies (1) to hold them to the lift arms.
1P1835 Bearing Puller
Assembly 1
1P1831 Bearing Puller
Assembly 1
start by:
a) remove bucket positioner 2. Fasten a hoist to the lift arms as shown. Lift the
b) remove bucket arms until tooling (B) can be installed.
75

LIFT ARMS
3. If necessary use tool (A) and clean the threads of
the cylinder and lift arm pins.
4. Remove the bolt that holds the tilt cylinder rod
pin. Fasten a hoist to the tilt cylinder and install
tooling (B). Remove the pin and lower the cylin
der rod to the axle housing. Remove the hoist.
NOTE: Tooling (B) can not be used on the right side.
5. Remove the bars that hold the lift cylinder rod
pins and install tooling (C). Remove the pins and
lower the cylinder rods to the frame.
6. Remove the bolts that hold the lift arm pins in
position. Install tooling (B) and remove the pins.
7. Remove the lift arms. The weight of the lift arms
is 1540 lb. (693 kg).
8. Remove seals (2) from the frame end of the lift
arms.
9. Use tooling (D) to remove the bearings from the
frame end of the lift arms.
10. Remove seals (3) from the bucket end of the lift
arms.
11. Use tooling (E) to remove the bearings from the
bucket end of the lift arms.
76

LIFT ARMS
INSTALL LIFT ARMS 6119-12
Tools Needed A B C
9S5559 Stud 1
1P1831 Bearing Puller Assembly 1
1P543 Nut 1
5H9817 Hydraulic Puller Assembly 1
9S5558 Stud 1
1P544 Nut 1
1P1835 Bearing Puller Assembly 1
1. Use tooling (A) to install the bearings in the

bucket end of the lift arms until the bearings are in
the center of their bore.
2. Use tooling (B) to install the bearings in the

frame end of the lift arms, until the bearings are in
the center of their bore.
3. Use tool group (C) to install the seals on each side

of the bearings. Make sure the lip of the seals is
toward the outside as shown.
4. Fasten a hoist to the lift arms and put them in

5. Install the pins that hold the cylinder rods and lift
arms in position. Install the bolts that hold the
pins. Put clean grease in the pins.
6. Remove the chains from lever assemblies (1).

Remove the hoist from the lift arms.
end by:
a) install bucket
b) install bucket positioner
77

HYDRAULIC CONTROL VALVE

REMOVE HYDRAULIC CONTROL
VALVE 5051-11
A WARNING
I. Drain the oil from the hydraulic tank. The capac

920-17.5 U.S. gal. (66 litre)
930-19.5 U.S. gal. (74 litre)
2. Remove fender (2), cover (3) and the cover from

the bottom of the hydraulic tank.
3. Remove cover (1) and the gasket from the hy

draulic tank.
4. Remove baffle assembly (4) and the O-ring seal

from the oil filter housing.
5. Remove bolts (5) and (6) to disconnect the tilt

and lift lever linkages. 6
6. Disconnect hose assembly (7) from the bottom of

the hydraulic tank.
78


7. Disconnect four tube assemblies (9) and (10)
from the bottom of the hydraulic tank.
NOTE: Drain valve (8) was removed for better photo

illustration of the location of bolts (11).
8. Remove bolts (11) that hold the hydraulic control

valve in position.
9. Move control valve (12) to the left. Remove bolt

(14). Loosen bolt (15) and remove strainer (13).
10. Two persons are needed to remove control valve

(12) from the hydraulic tank. The weight of the
control valve is 65 lb. (29 kg).
INSTALL HYDRAULIC CONTROL

VALVE 5051-12
1. Two persons are needed to put the control valve

in the hydraulic tank. Make sure the O-ring seals
are held in position with clean grease before
control valve (1) is put on the make-up valve
body.
2. Put strainer (3) in position under bolt (2) and

install the second bolt that holds it. Tighten the
two bolts. 3
3. Install the two bolts that hold control valve (1) in

position from the bottom of the hydraulic tank.
Tighten the bolts to a torque of 65 ± 3 lb.ft. (90
± 4 N-m).
79

VEHICLE SYSTEMS

connect the four tube assemblies (5) and hose
assembly (4) to the bottom of the hydraulic tank.
5. Put the tilt and lift linkages in alignment with the

valve spools and install bolts (6) and (7). Tighten
the bolts to a torque of 14 ± 2 lb.ft. (19~± 3
N-m).

install baffle assembly (8).
7. Install fender (10), the two covers to the bottom

of the hydraulic tank, the gasket and cover ( 9 ) .

level. 9
9. See LOADER HYDRAULIC SYSTEMS in

TESTING AND ADJUSTING for the relief
valve settings.
80


DISASSEMBLE HYDRAULIC CONTROL
VALVE 5051-15
start by:
a) remove hydraulic control valve
1. Remove baffle assemblies (4) and (5) from the

control valve.
2. Remove body (3), tilt relief valve groups (1),

plugs (2) and the O-ring seals from the control
valve.
3. Disassemble tilt relief valve groups (1) as fol

lows:
Remove plug (13), shims (12), springs (11) and
(10), washer (9) and valve (8) from body (7).
Remove O-ring seal (6) from body (7).
4. Remove relief valve group (14) from body (3).

Remove the two O-ring seals and back-up ring
from valve group (14).
NOTE: Do not disassemble valve group (14). There are

no serviced parts to this assembly so use a new part for
replacement if necessary.
5. Hold the tilt and lift valve stems in valve body

(15) so they will not turn. Loosen detents (17)
from the valve stems.
A WARNING
Retainers (16) have spring tension on them.

Remove the bolts that hold the retainers
slowly. 6
6. Remove the bolts that hold retainers (16) to valve A557 t 4X1
body (15).
81


7. Remove retainers (16), spacers (22), springs
(21), spacers (20), valve stems (18) and (19)
from valve body (15).
8. Remove plugs (23), the shims, springs and balls

to remove detents (24) and spacers from retainers
(16).
A56353X1
9. Remove the two plugs (26) and O-ring seals from

valve body (15).
10. Remove the three plugs (27) and O-ring seals

11. Remove plugs (25), (28), the O-ring seals,

springs and valves from valve body (15).
ASSEMBLE HYDRAULIC CONTROL

VALVE 5051-16
CAUTION
All parts must be kept clean. Use paper free of
lint and clean solvent to clean the parts. Put
clean hydraulic oil on all of the parts before
they are assembled.
I. Install the two plugs (4) and O-ring seals in valve

body (1).
2. Install the three plugs (3) and O-ring seals in

valve body (1). 3
3. Install valves (5), springs (6), the O-ring seals,

plugs (2) and (7) in valve body (1).
82


4. Install tilt valve stem (8) and lift valve stem (9) in
valve body (1) as shown.
5. Install detent (11) and spacer (12) in retainer (10)

as shown for the tilt valve stem.
6. Install detent (15) and spacer (14) in retainer (13)

as shown for the lift valve stem.
7. Install balls (16), springs (17), shims (18) and

plugs (19) in the retainers to hold the detents.
Tighten plugs (19) to a torque of 9 ± 2 lb.ft. (12
±3 N-m).
8. Install the three spacers (20), two springs (21)

and spacer (22) on the valve stems.
NOTE: Spacer (22) must be installed in the position

shown on the lift valve stem.
9. Put 9S3263 Thread Lock on the threads of both

detents. Make sure the detents are visually in
alignment with the valve stems and install retain
ers (10) and (13) in the positions shown.
10. Tighten the detents in the ends of the valve stems

to a torque of 27 ± 3 lb.ft. (38 ± 4 N-m).
83


11. Install O-ring seal (23), the back-up ring and
O-ring seal (25) on valve group (24). Make sure
the back-up ring for O-ring seal (25) is toward
O-ring seal (23).
12. Install valve group (24) in body (26).
13. Assemble the two tilt relief valve groups as fol

lows:
Install valve (29), washer (30), springs (31) and
(32), shims (33) and plug (34) in valve body (28).
Tighten plug (34) to a torque of 100 ± 5 lb.ft.
(135 ± 7 N-m). Install O-ring seal (27) on valve
body (28).
NOTE: See LOADER HYDRAULIC SYSTEM in

TESTING AND ADJUSTING for the correct pressure
setting of the relief valve groups.
14. Install the O-ring seals, plugs (36) and tilt relief
valve groups (35) in the valve body. Tighten
valve groups (35) to a torque of 50 ± 3 lb.ft. (70
± 4 N-m).
15. Put the O-ring seal in position on body (26) and

install it on the valve body.
16. Install the O-ring seals and baffles (37) and (38).
Tighten the bolts that hold the baffles to a torque
of 65 ± 3 lb.ft. (90 ± 4 N-m).
end by: A56352X1
a) install hydraulic control valve
84

MAKE-UP VALVE
REMOVE AND INSTALL MAKE-UP
VALVE 5117-10
Tools Needed A
1P1853 Pliers 1
start by:
a) remove hydraulic control valve
1. Remove the two bolts (1) that hold the valve body
in position. Remove the valve body from the
hydraulic tank.
2. Remove the O-ring seals from valve body (2).
3. Use tool (A) and remove rings (3).
A55513X1
4. Remove washers (4), springs (5) and valves (6)

5. Put clean hydraulic oil on the parts of the make

up valve.
6. Put valves (6), springs (5) and washers (4) in

valve body (2). Use tool (A) to install rings (3) to
hold the valves.
7. Install the O-ring seals in valve body (2) and use

clean grease to hold them in position. 8
8. Put valve body (2) in position in the hydraulic

tank and install bolts (l) to hold it.
end by:
a) install hydraulic control valve
85

LIFT AND TILT CONTROL LEVER HOUSINGS

REMOVE LIFT AND TILT CONTROL
LEVER HOUSINGS 5100-11
A WARNING
disconnected in the hydraulic system. 2 3 4 5 6 7

920-17.5 U.S. gal. (66 litre)
930-19.5 U.S. gal. (74 litre)
3. Remove cover (1) and the gasket from the hy

draulic tank.
4. Remove bolts (2) and (3) to disconnect the lift

and tilt linkages from the control valve spools.
5. Lift the seat and put blocks in position to hold it

up.
6. Disconnect rod ends (4) and (7) from the lift and
tilt control lever housings.
7. Remove the bolts and remove lift control lever

housing (6) and tilt control lever housing (5) from
the back of the hydraulic tank.
NOTE: The housings will have to be turned as they are

pulled out of the hydraulic tank to give clearance for the
linkage.
86


INSTALL LIFT AND TILT CONTROL
1. Put the gaskets, lift control lever housing (2) and

tilt control lever housing (3) in position on the
back of the hydraulic tank. Install the bolts to
hold the housings.
2. Connect lift linkage (1) to the lift control lever

housing (2). Connect tilt 1 inkage (4) to tilt control
lever housing (3).
3. Lower the seat to its original position.
4. Install bolts (5) and (6) to connect the linkage to

the control valve spools. Tighten the bolts to a
torque of 14 ± 2 lb.ft. (19 ± 3 N-m).
5. Install the gasket and cover (7) on the hydraulic

tank.

level.
DISASSEMBLE LIFT AND TILT CONTROL

start by:
a) remove lift and tilt control lever housings
1. Loosen bolt (2) and remove lever (1), the key and A55S20X t
washer from the shaft.
87


2. Loosen the screw that holds the lever to shaft (4)
inside the housing.
3. Remove shaft (4) and the bearing from the side

opposite of seal (3).
4. Remove the bearing and key from shaft (4).
5. Remove lever (5) and link (8) from housing (7).
6. Remove pin (6) that holds lever (5) and link (8)
together.
7. Remove seal (3) and the bearing from housing

(7).
ASSEMBLE LIFT AND TILT CONTROL

Tools Needed A
1. Use tool group (A) and install the bearing and lip
type seal in housing (1). Make sure the lip of the
seal is toward the inside as shown.
2. Connect lever (2) and link (4) together with pin

(3).
NOTE: When lever (2) is installed in the housing the

head of pin (3) must be toward the lip type seal for the
lift control. The head of pin (3) must be toward the
opposite side of housing (1) for the tilt control. 3
3. Install lever (2) and link (4) in housing (1).
88

4. Install bearing (7) in the housing.
A55527X1
5. Install key (6) in shaft (5) and install shaft (5) in

the housing with key (6) in alignment with the
opening in the lever. Tighten the screw that holds
the lever to shaft (5).
A55528X1
6. Install washer (10), key (9) and lever (8) on the

shaft. Tighten the bolt that holds lever (8) to the
shaft.
end by:
a) install lift and tilt control lever housings
89

HYDRAULIC TANK
REMOVE HYDRAULIC TANK 5056-11
start by:
a) remove cab
A WARNING


920-17.5 U.S. gal. (66 litre)
930-19.5 U.S. gal. (74 litre)
2. Remove cover (1), fender (2) and cover (3) from

the machine.
3. Remove cover (4) from the hydraulic tank.
4. Disconnect tube assembly (5) from the oil filter

housing.
5. Disconnect elbow (6), oil lines (7), (8) and (9)

from the bottom of the hydraulic tank.
6. Tilt the seat back.
90

HYDRAULIC TANK
7. Disconnect linkages (10) and (12) from the lift
and tilt control lever housings.
8. Disconnect oil lines (11) and (13) from the lift

kickout and bucket positioner slave cylinders.
9. Remove the three bolts (14) from the control

lever bracket. Remove bolt (15).
10. Remove bolts (16) and (17) from the top of the
hydraulic tank and install two 3/8”-16 NC forged
eyebolts in their place.
11. Fasten a hoist to the hydraulic tank.
, A55532X1
12. Remove bolts (19) from each side of the hy

draulic tank. Remove the tank. The weight of the
tank is 380 lb. (171 kg).
13. Remove blocks (18) from the frame.
91

HYDRAULIC TANK
INSTALL HYDRAULIC TANK 5056-12
1. Install two 3/8”-16 NC forged eyebolts in the top

of the hydraulic tank and fasten a hoist to it.
2. Put blocks (2) in position on the frame. Put hy

draulic tank (1) in position and install the bolts to
hold it to the frame.
3. Install bolt (4) and the three bolts (3) in the

bracket for the control levers.
4. Connect oil lines (6) and (8) to the lift kickout and
bucket positioner slave cylinders.
A55535X1
5. Connect linkages (5) and (7) to the lift and tilt

control lever housings. 6
6. Put clean hydraulic oil on the O-ring seals. Con

nect elbow (9), hose assembly (10) and the four
tube assemblies (11) to the bottom of the hy
draulic tank.
92

HYDRAULIC TANK
connect tube assembly (12) to the oil filter hous
ing.
8. Install cover (13) on the hydraulic tank.
9. Install fender (14), cover (15) and the bottom

cover on the hydraulic tank.

level.
11. Remove (bleed) the air from the lift kickout and
bucket positioner systems. See Install Bucket
Positioner Master Cylinder for this procedure.
end by:
a) install cab
93

HYDRAULIC PUMP
REMOVE HYDRAULIC PUMP 5055-11
A WARNING

920-17.5 U.S. gal. (66 litre)
930-19.5 U.S. gal. (74 litre)
2. Remove access cover (1) and fender (2) as a unit

from the machine. Remove access cover (3).
3. Remove access cover (4) from the machine. A55678XI
4. Remove elbow (5) and tube assembly (6) as a

unit.
5. Disconnect hose assemblies (9) and (10). Re

move tee (7) and tube assembly (8) from the
hydraulic pump.
NOTE: Tee (8) can not be removed until the bolts that
hold the pump in position are loosened.
6. Remove the two bolts (11) and remove pump

A55679X1
(12). The weight of the pump is 50 lb. (23 kg).
94

HYDRAULIC PUMP
INSTALL HYDRAULIC PUMP 5055-12
NOTE: Put clean hydraulic oil on all O-ring seals.
1. Put the O-ring seal on pump (1) and install the

pump on the machine.
NOTE: Do not tighten bolts (2) until tube assembly (3)

is installed.
2. Install bolts (2) to hold the hydraulic pump in

position.
3. Put the O-ring seal and tube assembly (3) in

position. Install the back flange and two bolts that
hold hose assembly (5).
4. Tighten bolts (2).
5. Put the O-ring seal in hose assembly (5) and

connect hose assembly (5) to the pump.
6. Put the O-ring seals in position and install tee (4).

Connect hose assembly (6) to the tee.
7. Install tube assembly (7) and elbow (8) as a unit.
8. Install access cover (9) on the machine.
9. Install access cover (11) and fender (10) on the

machine as a unit.
10. Install the access cover on the bottom of the

hydraulic tank.

level.
95

HYDRAULIC PUMP
DISASSEMBLE HYDRAULIC
PUMP 5055-15
Tools Needed A
1P1859 Pliers 1
start by:
a) remove hydraulic pump
NOTE: Put marks across the adapter, body and covers

for correct alignment when the pump is assembled.
I. Remove bolts ( l ) , adapter (2) and the O-ring seal

from the pump body.
2. Remove bolts (3) and cover (4) from the pump

cover. Remove the two O-ring seals and the
back-up ring from the cartridge assembly.
3. Remove the two seal rings (5) from cover (4).
4. Remove bolts (6) and body (7) from cover (8).

Remove the two O-ring seals and back-up ring
from the cartridge assembly.
5. Remove the two seal rings (9) from body (7).
A55689X1
6. Use tool (A) to remove ring (10) from the shaft.
96

HYDRAULIC PUMP
7. Remove shaft (11) from adapter end of body (7).
8. Remove the ring that holds bearing (12) in body

(7). Remove bearing (12) and washer (13).
9. Remove seal (14) from the inside of body (7).
A55699X1
10. Remove seal (15) from the adapter end of body

(7).
11. Remove cartridge assemblies (16) and (17) from A55693X1
pump cover (8).
97

HYDRAULIC PUMP
12. Disassemble both cartridge assemblies as fol
lows:
a) Remove screws (21) and make a separation of

plate (18), ring 19), plate (20) and plates
( 22) .
b) Remove rotor (23) from ring (19).
c) Remove vanes (24) and inserts (25) from

rotor (23).
d) Remove the seal and retainer assemblies (26)

from plates (18) and (20).
e) Remove seals (28) from retainers (27).
13. Check all of the parts of the pump for damage

(scratches, nicks and burrs). If the parts have
damage, use new parts for replacement. See
DIAGNOSING HYDRAULIC PUMP
FAILURES FORM NO. SEBD0501.
98

HYDRAULIC PUMP
ASSEMBLE HYDRAULIC PUMP 5055-16
Tools Needed A B
1P1859 Pliers 1
CAUTION
All parts must be kept clean and free of damage
(scratches, nicks and burrs). Use clean solvent
to clean all metal parts of the pump. Put clean
hydraulic oil on all parts of the pump at assem
bly.
1. Install O-ring seals (1) in each retainer (2).
2. Install the seal and retainer assemblies (4) in end

plates (3) and (5) with the O-ring seal toward the
end plates as shown.
3. Install inserts (8) in vanes (7). Install the vane

assemblies in rotor (6) with the sharp edge of the
vanes toward the direction of the arrow (direction
of rotation) as shown.
4. Install rotor (6) and the vane assemblies in ring

(10). Make sure the arrow on rotor (6) is in the
same direction as the arrow on the chamfer of
ring (10).
5. Install plates (9) and (11) on each side of ring

(10). Make sure the bronze side of the plates are
next to rotor (6).
6. Put end plates (3) and (5) with the seal and
retainer assemblies in position on the plates.
7. Make sure the notches on outside diameters of

plates (3), (9), (11) and (5) are in alignment.
Make an alignment of these notches with the
chamfers on ring (10) and install the two screws
that hold the cartridge assembly together.
NOTE: Make sure the end of ring (10) that has the
arrow on its chamfer is assembled toward end plate (3)
before the screws are tightened. 8
8. Do Steps 1 through 7 for the other cartridge

assembly.
99

HYDRAULIC PUMP
9. Install cartridge assemblies (13) and (14) in
pump cover (12) until the dowels of the cartridge
assemblies are in their bores in the cover.
10. Put O-ring seals (15) on both cartridge as

semblies and install back-up rings (16). Make A55704X1
sure the O-ring seals are toward cover (12).
11. Install the lip type seal in the outside counterbore

of pump body (17) with tool group (A). Make
sure the lip of the seal is toward the inside as
shown.
the inside of pump body (17). Make sure the lip
of the seal is toward the inside as shown.
13. Install washer (19) and bearing (18) in pump

body (17). Install the ring that holds bearing (19) A55706X1
in position.
100

HYDRAULIC PUMP
14. Install the shaft in pump body (17). Use tool (B)
to install ring (21) in the groove of the shaft.
15. Install the two seal rings (20) in pump body (17).
16. Put the O-ring seal in position on the cartridge

assembly. Install pump body (17) and the shaft
on cover (12). Tighten the bolts that hold body
(17) to a torque of 70 ± 5 lb.ft. (95 ± 7 N-m).
17. Install the two seal rings (22) in cover (23).
18. Install O-ring seal (24) on the cartridge assem

bly. Put cover (23) in position and tighten the
bolts that hold it to a torque of 45 ± 5 lb.ft. (60 ±
7 N-m).
19. Install O-ring seal (26), adapter (25) and the bolts
to the pump body.
end by:
a) install hydraulic pump
101

CAB
REMOVE CAB 7325-11
1. Disconnect washer hose (1) from the nozzle as

sembly.
A56307XI
.. -• -BiCi
2. Remove panel (2) and disconnect the wire for the

windshield wiper motor.
3. Remove windshield washer reservoir (3) from

the bracket on the left side of the cab.
4. Remove bolts (4) and the nuts from under each

side of the cab.
5. Remove the twelve bolts (5) that hold the back of

the cab. 6
6. Fasten a hoist and remove the cab from the

machine. The weight of the cab is 850 lb. (388
kg).
102

CAB
INSTALL CAB 7325-12
1. Fasten a hoist and put the cab in position on the

machine.
2. Install the twelve bolts (1) that hold the back of

the cab.
3. Install the twelve bolts (2) and four nuts that hold
the front of the cab in position.
4. Put the windshield washer reservoir in its bracket

on the left side of the cab.
5. Connect windshield washer hose (3) to the nozzle

assembly. 6
6. Connect wire (4) for the windshield wiper motor

to panel (5). Install panel (5).
103

LOADER MAIN FRAMES

SEPARATION OF LOADER MAIN
FRAMES
Tools Needed A B
2B9886 Hydraulic Jack 3
8B7554 Bearing Cup Puller Attachment 1
1S5188 Leg 2
1. Put blocks in front and behind the front tires.
2. Install a block (1) between the rear frame and

axle housing on each side of the machine to A57000X1
prevent side movement of the rear frame.
A WARNING
Stop the engine, lower the bucket to the ground
and move the control levers backward and for
ward to release the pressure in the hydraulic

920-17.5 U.S. gal. (66 litre)
930-19.5 U.S. gal. (74 litre)
4. Remove bolts (2) from each end of intermediate
drive shaft (3) and remove the drive shaft.
5. Remove bolts (4) and the washers. From the top
of the front frame remove the pins that hold the
steering cylinder rods.
6. Disconnect the brake chamber rod end from the
emergency and parking brake. See Remove
Emergency and Parking Brake for this proce
dure.
A WARNING
Open the drain valve on the air tank and remove
the air pressure from the system before any
brake or air lines are disconnected. 7
7. Disconnect brake line (5) from the front frame.
104

LOADER MAIN FRAMES

8. Remove floor plates (6).
9. Put identification on hydraulic hose assemblies

(7), (8), (9) and (10) for correct installation.
Disconnect the hose assemblies from the front
frame.
10. Disconnect air line (12) from the horn valve and
pull it to the front frame.
11. Put identification on oil lines (11) for correct

installation. Disconnect oil lines (1 l)from the lift
kickout and bucket positioner slave cylinders (the
slave cylinders are found under the operators
seat).
12. Install two of tooling (A) under the front frame

for support.
13. Put a floor jack in position under the output

transfer gear case.
14. Fasten a lift truck to the rear frame as shown.
15. Remove plate (13) and the shims from the bottom
of the front frame.
105

LOADER MAIN FRAMES

16. Use one of tooling (A) to push the lower pivot pin
out of the frames.
17. Use tooling (B) to remove spacer (14) as shown.

The spacer must be removed before separation of
the frames can be made.
18. Remove the bolt that holds wire assembly (16)

and move the wire assembly from the upper pivot
pin plate. Install the bolt in the pivot pin plate.
19. Remove the four bolts (15) that hold the pivot pin
plate to the frame.
20. Install two V6”-13 NC forcing screws in pivot pin

plate (17) and remove the upper pivot pin.
21. Use the lift truck and floor jack to pull the rear
frame from the front frame.
22. Put blocks under the front of the rear frame for
support. Remove the floor jack and lift truck
from the rear frame.
106

LOADER MAIN FRAMES

CONNECTION OF LOADER MAIN FRAMES
Tools Needed A B C
2B9886 Hydraulic Jack 2 1
5P7304 Spacer 1
9S9149 Wrench 1
1. Fasten a lift truck to the back of the rear frame.
2. Put a floor jack in position under the output

transfer gear case. Remove the blocks used for
support from under the front of the rear frame.
3. Make sure the blocks are in position in front and

behind the front tires and the weight of the front
frame is on tooling (A).
4. Push the rear frame into position on the front

frame with the lift truck.
5. Make an alignment of the bores in the main

frames and install upper pivot pin (1). Tighten the
four bolts (in a sequence of two opposite comers
at a time) that hold the upper pivot pin plate.
After the pivot pin is in the correct position the
bolts must be tightened to a torque of 50 ± 25
lb.ft. (70 ± 35 N-m). Bend the locks on the bolts.
6. Remove one of the center bolts from the upper

pivot pin plate. Move the wire assembly and clip
in position over the plate and install the bolt. 7
7. Install lower pivot pin (2) as shown.
8. Use tooling (B) to install spacer (3) for the lower

pivot pin.
107

LOADER MAIN FRAMES

9. Put plate (4) in position on the machine and
install two of the bolts that hold it 180° apart.
Tighten the bolts to a torque of 15 lb.ft. (20
N-m).
10. Measure the distance between plate (4) and the

frame (360° around the plate) with a feeler gauge.
Make a note of the minimum measurement.
11. Remove plate (4) and install shims (5) that have a
thickness of the minimum measurement taken in
Step 10 minus .010 in. (.25 mm). Install the plate
and tighten the seven bolts.
12. Connect oil lines (6) to the lift kickout and bucket
positioner slave cylinders.
A57020X
13. Connect air line (7) to the horn valve.
14. Connect hose assemblies (8), (9), (10) and (11)

to their correct location on the front frame.
108

LOADER MAIN FRAMES
15. Connect brake line (12) to the front frame.
16. Put intermediate drive shaft (13) in position and

install the bolts to hold it. Tighten the bolts to a
torque of 45 ± 5 lb.ft. (60 ± 7 N-m) with har
dened washers.
17. Put both steering cylinder rods (15) in position

with washers (16) on each side of the rods to
make the steering cylinders level. Install pin
(14), the bolts and washers.
18. Install the two floor plates on the machine.
19. Remove the lift truck, tooling (A) and the blocks
between the axle housing and rear frame.

level.
21. Use tool (C) and remove (bleed) the air from the
brake system. See HYDRAULIC BRAKE SYS
TEM SERVICING in TESTING AND AD
JUSTING.
22. Remove (bleed) the air from the lift kickout and
bucket positioner systems. See REMOVE AND
INSTALL LIFT KICKOUT MASTER CYLIN
DER for this procedure.
109

PIVOT PIN BEARINGS

REMOVE PIVOT PIN
BEARINGS 7057-11
Tools Needed A B C D
5P2997 Hydraulic Puller
Assembly 1 1
9F4918 Ring Compressor 1 1
5P4184 Stud 1 1
7H7539 Nut
(1 1/4"-l2 NF Hardened) 1 1
4K684 Washer
(1 Va” Inside Diameter) 1 1
5P3100 Pump Group 1 1 1 1
7F9540 Flydraulic Puller 1 1
6H1627 Spacer (part of 6H3202
Adapter Assembly) 1
5F4776 Stud 1 1
5F7351 Nut (part of 8B7548
Puller Assembly) 1 1
5F7353 Washer (part of 8B7548
Puller Assembly) 1 1
1P1834 Bearing Puller Adapter 1 1
5F7334 Spacer Group) 1
start by:
a) separation of main frames
1. Remove the lower pivot pin bearings from the

rear frame as follows:
a) Remove spacer (1) from upper cap (2).
b) Remove the bolts to remove lower cap (3),
upper cap (2) and the shim from the rear
frame.
c) Remove the lip type seals (4) from upper cap
(2) and the lower cap.
d) Use tooling (A) to pull the two bearings out of
the rear frame. 2
2. Remove the middle pivot pin bearing from the

rear frame as follows:
a) See Remove Steering Control Valve to re-
.move the steering control valve.
b) Install tooling (B) and pull the bearing out of
the rear frame.
110

PIVOT PIN BEARINGS

3. Use tooling (C) to pull the upper pivot pin bear
ing from the rear frame.
4. Remove the upper pivot pin bearing seals (5)

from each side of the front frame.
5. Pull the upper pivot pin bearing from the front

frame with tooling (D).
INSTALL PIVOT PIN

BEARINGS 7057-12
Tools Needed A BCD E F

7F9540 Plydraulic Puller 1 1
5P4776 Stud 1 1
5F7351 Nut (part of
8B7548 Puller Assembly) 1 1
5F7353 Washer (part of
8B7548 Puller Assembly) 1 1
1P1834 Bearing Puller Adapter 1 1
FT888 Adapter 2
8S9089 Bolt
(y2”-13 NC x 4 Vz" long) 1
1D4719 Nut (1/2”-13 NC) 1
4B4280 Washer
(Vz" Inside Diameter) 1
6H1627 Spacer (part of
6H3202 Adapter Assembly) 1
5P2997 Hydraulic Puller
Assembly 1
5P4184 Stud 1
7H7539 Nut
(1 1/4”-12 NF Hardened) 1
4K684 Washer
(1 'A" Inside Diameter) 1
111

VEHICLE SYSTEMS
PIVOT PIN BEARINGS

1. Use tooling (A) and install the upper pivot pin
bearing in the front frame. Install the bearing
until it is in the center of its bore or .56 ± .02 in.
(14.22 ± 0.51 mm) from the top surface of the
frame.
2. Use tool group (B) and install the seals in each

side of the front frame until they make contact
with the bearing. Make sure the lip of the seal is
toward the outside of the frame as shown.
3. Install the seal in upper cap (1) for the lower pivot
pin bearings with tool group (C). Install the seal
until it makes contact with the counterbore in the
cap and with the lip of the seal toward inside of
the cap.
4. Install the seal in the lower cap for the lower pivot
pin bearings with tool group (C). Install the seal
until it makes contact with the counterbore in the
cap and with the lip of the seal toward outside of
the cap.
5. Put lower bearing cap (2) in position and install

three of the bolts to hold it the same distance
apart.
6. Lower the temperature of the lower bearing cup

to -100°F ± 10°F (—73.3°C ± -23.3°C). Use
tool group (C) and install the bearing cup until it
makes contact with cap (2).
7. Put clean oil on the two bearing cones and install

them in the lower pivot pin bore. 8
8. Lower the temperature of the upper bearing cup

to -100°F ± 10°F (—73.3°C ± -23.3°C). Use
tool group (C) and install the bearing cup until it
makes light contact with the upper bearing cone.
112

VEHICLE SYSTEMS
PIVOT PIN BEARINGS

9. Remove the three lower bearing cap bolts and
install upper cap (1) and the shim. Install three
bolts the same distance apart to hold caps (1) and
( 2) .
10. Connect tooling (D) to the bearing cones. Check

the amount of torque needed to turn the bearing
cones. Remove or install shims under cap (1)
until the following torque is needed to turn the
bearing cones:
920-20 to 75 lb.in. (2.3 to 8.5 N-m)
930-25 to 125 lb.in. (2.8 to 14.1 N-m)
11. Install the remainder of the bolts that hold the

bearing caps.
12. Lower the temperature of the middle pivot pin

bearing to — 80°F ± 10°F (62.2°C ± —23.3 C).
Use tooling (E) to install the bearing until it is
even with the surface of the rear frame.
13. Install the steering control valve. See Install

Steering Control Valve for this procedure.
14. Use tooling (F) to install upper pivot pin bearing

(3) in the rear frame until the large outside diame
ter of the bearing is in contact with the counter
bore of the frame.
end by:
a) connection of loader main frames
113

cs CATERPILLAR
Caterpillar, Cat and CB are Trademarks of Caterpillar Tractor Co.
CATERPILLAR FUNDAMENTAL ENGLISH DECEMBER 1977

PRINTED IN U.S.A.
FORM NO. REG00976-01


Cat 920 930 Wheel Loaders System

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FORM NO.

DISASSEMBLY AND ASSEMBLY

920 & 930 WHEEL LOADERS

BDC for engine manuals and specs

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

BDC for engine manuals and specs

Improper performance of lubrication or

BDC for engine manuals and specs

BDC for engine manuals and specs

GENERAL TIGHTENING TORQUE FOR

THREAD DIAMETER STANDARD TORQUE

inches millimeters lb. ft. N-m*

Use these torques for bolts and nuts on

Use these torques for studs with Taperlock threads.

1/4 6.35 5 2 ± 7+3

*1 newton meter (N-m) is approximately the same as 0.1 mkg.

BDC for engine manuals and specs

Brake Control Valves................................................................................................. ......... 7

BDC for engine manuals and specs

BDC for engine manuals and specs

RIM AND TIRE

NOTE: The bucket is removed for better photo illustra­

1. Lift the machine and put tooling (A) in position

2. Fasten a hoist to the tire.

3. Remove nuts (1) and remove the rim and tire.

4. Fasten a hoist to the rim and tire and put it in

5. Install nuts (1) and tighten them to a torque of

6. Lift the machine and remove tooling (A). Lower

7. See LUBRICATION AND MAINTENANCE

BDC for engine manuals and specs

BRAKE CONTROL VALVES

NOTE: The right brake control valve is shown, use the

I. Put identification on electric wires (l) as to their

2. Disconnect the four airlines (3), (4), (5) and (one

3. Remove the pin that holds pin (7). Remove pin

4. Remove boot (9) from the valve assembly. Re­

INSTALL BRAKE CONTROL

1. Put valve assembly (1) in position and install the

2. Connect air lines (2) and (3) to valve assembly

3. Connect the electric wires to their correct loca­

BDC for engine manuals and specs

BRAKE CONTROL VALVES

4. Install the boot on the valve assembly.

5. Put treadle assembly (5) in position and install

6. Start the engine and inspect the system for leaks.

DISASSEMBLE BRAKE CONTROL

NOTE: Steps l, 2 and 3 are for the right side brake

1. Remove stop light switch (4) and the fitting from

NOTE: The parts of check valve (1) can not be ordered

3. Remove cap (12), gasket (11), retainer and seat

BDC for engine manuals and specs

BRAKE CONTROL VALVES

4. Remove retainer (13) from valve body (3).

5. Remove piston assembly (14) and spring (15)

6. Remove O-ring seal (19), bolt (17), washer (18),

Spring on valve assembly (23) is under com­

7. Turn the brake valve body over as shown. Re­

8. Twist valve (28) and pull it away from seat (24).

9. Remove screw (26), washer (25), diaphram (27)

NOTE: The bucket is removed for better photo illustra

4. Remove boot (9) from the valve assembly. Re

3. Connect the electric wires to their correct loca

Spring on valve assembly (23) is under com

7. Turn the brake valve body over as shown. Re

2. Remove the nuts that hold actuators (3) in posi

2. Remove the bolts and nuts to remove band as

3. Make an alignment of the marks on plate assem

4. Install band assembly (5) to hold the unit to

1. Remove the cap from the main brake fluid reser

3. Remove the cap from master cylinder (2). Dis

4. Remove the bolts and nuts that hold master cy

1. Push the brake pistons into the brake head as