Troy-Bilt 14066 User's Manual
Contents
1. 4000 PSI Test Gauge Fitting 90 Fig 15 Relief Valve Tesi TROUBLE SHOOTING This Trouble Shooting Chart is provided for reference to possibie Loader Cperational Problems Determine the Problem thz best describes the operational problem being xperienced and eli ate the Possible Causes as lis by following the Correction procedures For further assistance contac sur dealer PROBLEM Lift and Bucket Cylinders inoperative Lift or Bucket Cylinders Inoperative Lift and or Bucket Cylinders Operate in Wrong Direction Relative to Control Valve Lever Position POSSIBL CAUSE Low Hydraulic Fluid level Hydraulic hoses connected incorrectly Hydraulic Hoses to from Control Valve Blocked Loader Control Valve stuck Open Low System pressure s0 plied from Hydraulic Pu np Control Valve Linkage roken Quick Disconnect Coup ler s are not fully connected or Flow Check Hydraulic Hose or Tubeline Blockage Cylinder Piston Assembly defective not sealing Control Valve blockage Hydraulic hoses connected incorrectly 100 1 CORRECTION Check and replenish Hycrewlic riuid Check and correct hydraulic hos connections Check for damaged kinked hoses etc Check system pressure Re pair or repiace Relief Valve Check system pressure Re fer to Hydraulic Pump Capacity Inadequate Inspect Repair as required2. Give Operators Manual to the customer and ask him to familiarize himself with ail sections Explain to the customer that when the tractor and loader combination is transported on public roads and highways at night or during the day accessory lights warning devices or a Siow Moving Vehicle emblem should be used to properly warn operators of other vehicles Check with local law enforcement officials for specific regulations 3 Beginning Each Season Checklist Check all hydraulic hoses lines and fittings to be sure they are tight and not leaking Replace any worn or damaged parts Check hydraulic fluid level and add as required Use Type A Hydraulic Fluid or Equivalent Operate loader by raising and lowering lift arms and extending and retracting bucket cylinders Check all hydraulic cylinders for leakage around seals Repair as required Review Safety Precautions Section of manual Make sure loader has been completely lubricated per Lubrication section prior to beginning operation Check all bolts on loader mounting frame to be sure they are properly tightened to specified torque value Check for any special attachment which will help you do a better job Product Graphics Read all Safety decals gt machine as shown below 3 IMPORTANT i LOADER HYDRAULIC SYSTEM FLUID 3 LEVEL SHOULD BE CHECKED DAILY OR EVERY 1O HOURS OF OPERATION i i TO MAINTAIN FLUID AT SPECIFIED LEVEL LOADER BOOM SHOULD
3. ________ mmm eo 44 40 2 50 4 50 2 60 1 60 1 60 1 60 1 60 1 70 1 80 1 80 1 80 1 80 4 90 1 90 1 90 3 90 5 90 9 Trouble Shooting _______ ggg Hydraulic System Schematic H _______ tig g Attachments and Accessories ee GENERAL INFORMATION Introduction The purpose of this manual is to assist you in maintaining and operating your BOLENS loader Read it carefully it furnishes information and in structions that will help you achieve years of dependable performance Some information may be general in nature due to unknown and varying conditions However through experience and these instructions you should be able to develop operating procedures suitable to your particular situation Right and Left as used throughout this manual are determined by facing the direction the machine will travel when in use The photos illustrations and data used in this manual are current at the time of printing but due to possible in line production changes your machine may vary slightly in detail Extra equip ment that may be shown on the machine is op tional at extra cost The Manufacturer reserves the right to redesign and change the machine as may be necessary without notification Important Illustrations used in this Manual may not show all safety equipment that is recommended to en sure safe operation of tractor loader Refer to Safety Section of this Manual and
4. Check Coupler connections Replace coupler s if necessary Check for evidence of damage to hoses or tube lines that would block flow of oil between cylinders and control valve Check cylinders for internal leakage as described in service section under Cylinder Leakage Tests Inspect for biockage Disas semble valve if necessary Correct hydraulic hose con nections PROBLEM Slow or Erratic Lift TROUBLE SHOOTING POSSIBLE CAUSE Low Hydraulic Fluid level Coid Hydraulic Fluid Engine R P M too slow Hydraulic Pump F 7 M too slow Excessive weight in bucket Material weight exceeds maximum specified Loader capacity Control Valve Linkage binding defective Aeration of Hydraulic Fiuid Quick Disconnect Coupler Restriction or Coupler Flow Checks Orifice Plate installed upside down Hydraulic Hose or Tubeline Restriction Hoses Tubeline kinked or pinched Lift Cylinder Piston Assembly Leakage Relief Valve Erratic or Set Below Specifications Control Vaive Leaking internally Bypassing fluid within valve Inadequate Hydraulic Pump Capacity 100 2 H Cm SE Bo mir As SIAR AS 1 ION i Check regie sisi Hydraulic FYAL Allow nycvaulic system to warm up to operating temperature Increas2 angine speed To obtain SatisfacTory loads operation Reduce material foads Check control valve linkage and repair if worn defective Refer to Aeration of Hydraul
5. INSTITUTIONAL INDUSTRIAL RENTAL DEMONSTAATCA CE YEAR LIMITED WARRANTY The Commercial Institutional industrial Rental and Demonstrator Limited Warranty covering detects on material and workmanship will be for a period of one 1 year from date of purchase on ail Bolens Troy Bilt and W W Grindar units and their manufactured attachments This warranty applies to the originai purchaser oniy Engines manufactured by Briggs amp Stratton Kohler and Tecumseh and transmissions manufactured by Peerless will also be warranted for this one 1 year warranty period through the authorized repair stations of their respective manufacturers IV GENERAL INFORMATION Garden Way Inc s obligation under this warranty is limited to the repair or replacement at its option by an authorized Garden Way equipment dealer of any part found to be defective in material or workmanship without charge for parts and labor In order to obtain warranty service the owner is responsible for 1 Providing proof of purchase documentation ownership registration or copy of bill of sale 2 Informing any authorized Garden Way equipment dealer of the defect and making the product available for repair Charges for pick up delivery and service calls are not covered by this warranty This warranty does not cover defects malfunctions or failures caused by 1 Use of unauthorized accessories or attachments 2 Lack of reasonable and necessary maintenance
6. larger than the bucket above hood height 31 1835750 i 595 2053 PRODUCT GRAPHICS Keep safety product graphics decals clean Replace any safety product graphics that are damaged destroyed missing painted over or can no longer be read Replacement safety pro duct graphics are availalbe through your dealer SAFETY Graphics Produc 30 2 SAFETY Saieiy Precautions WATCH OUT for this symbci througheuT this bozk It wit direct your atisnt to information that involves your safety For your own protection and for the protection of others near the machine study following list of safety precautions Fuifiii your responsibility ci informing anyone else operating the 3chine of these precautions improper use of a loader can cause serious injury r death Learn and practice safe 3e of controls before operating It is your respcasibility to understand and follow manufacturer s instructions on machine operation and service and to observe pertinent laws and regulations It is also your responsibility to be certain that anyone other than yourself operating the loader is aware of safe operating practices and potential hazards Clear the area of other persons Operate the loader from the tractor seat only Prohibit others especially children from climbing or riding on machine or being too close while machine is operating Do not stand walk or work under a raised loader or attachment u
7. csscccsssscssessssseccssssecessesesecsesssassrsasssecsssuvssessscuseecessecessesecees Attachment Rollback Angle Digging Depth Selow Grade rFrommouoowrp 3 D o 5 5 gt amp Q gt 3 QO 5 bad o 5 A y o Z 3 a Lift Capacity to Full Hegh h 350 Ibs LAP CYNON sisi seks sscsusvecsietaesttcssisscouednacsea di causeetiguas sncste cue ot asivaccanlasecetotescsornce cs g at ne ae 1 5 x 11 5 Relief Valve Pressure Setting c cccsecsssssssssscesssssescecssesssssssesecsesscsesscsssssesstssssessesscaserescceseeses 1400 psi Material MER tess sau EE E E pores febdk esta Ge saci sels ob ui Ha TA 40 CYCLE TIMES Idle 1 2 Throttle Full Throttle Lift Boom 7 6 sec 2 9 sec 2 4 sec Lower Boom 4 1 2 2 2 1 Dump Bucket 3 4 1 4 1 3 Retract Bucket 5 1 2 0 1 7 Bucket Width 40 Cu Yd 16 VADER SPECIFICAT NS Material Bucket Capacities Struck Capacity nated Hes Cu Fi Cu Meters Cu Yd Cu id 4 2 12 19 5 0 40 2 a LUBRICAT Do not perform ar vice Maintenance Opera tions with loader raised off ground For addi tional acces to tractor components remove loader important Lower the loader to the ground and relieve pressure in baie hydraulic lines prior t3 perfor ming any service maintenance cperationa on the tractor or oa mm Escaping fluid under ressure can have sufficien force to penetrate the skin causing serious injury Before disconisc
8. mediately following installation stort p as described under Relief Vaive Acjusiment Check for hydraulic leaks and ensure hose routings do not result in hydraulic hoses rubbing or catching on adjacent tractor lioader com ponents SERVICE Relief Valve Test Adjustment important Safety glasses should be worn when performing this adjustment Install a 0 4000 PSi Test Gauge into the unused Loader Control Valve pressure port IN at the Control Valve Fig 15 Start tractor and run engine at operating speed to bring hydraulic fluid up to normal operating temperature With engine at maximum R P M shift loader con trol valve bucket cylinder spool to fully retract bucket cylinders and hold in this position to ob tain hydraulic system relief pressure Observe pressure reading on Test Gauge Important Do not maintain Hydraulic System at Relief Pressure for more than 10 second intervals to prevent overheating of hydraulic system Adjust Relief Pressure to specification by remov ing Relief Valve Cap loosening Locknut and tur ning Adjustment Screw In clockwise to increase Relief Pressure Out counter clockwise to decrease Relief Pressure Note Refer to Loader Specifications for Relief Valve Setting Retorque locknut and reinstall Relief Valve Cap Recheck relief pressure Shut tractor OFF remove Test Gauge and recon nect hydraulic lines Start tractor and check for leaks
9. siowly back out of pile For maximum loading efficiency minimize angle of turn and distance between the Loading and Unloading points Transporting Material 70 3 Transporting material to Unloading Point w h Loader Bucket as low as possible to prevent spillage and maintain maximum Tractor Loac r stability Important During ansport the loader should not be in a position that will impair operator s vision Observe the following safety messages A WARNING A loaded bucket should be transported in a low position at slow ground speeds especially if the ground is irregular Make turns slowly and use the tractor brakes cautiously A full bucket in the raised position alters the center of gravity location of the unit and increases the possibility of mishaps A WARNING Do not lift or carry personnel on a loader or attachment a slip or fall could cause bodily injury OPERATION Unloading As the tractor approaches the Unloading Point raise the loader to the height required for clearance to Dump bucket Drive slowly to position bucket above Unloading Point stop tractor and dump bucket Note Do not raise loader higher than required for Dumping clearance As Dumping clearance height increases the bucket position must be adjusted to maintain a level bucket to prevent excessive spillage of material from bucket DANGER Load on raised bucket can roll back onto operator
10. the Tractor Operator s Manual for information concerning safety equipment Consult your Dealer for further information Warranty Registration The Warranty Registration form must be filled out and signed to validate your warranty See your Dealer for Details 10 1 Serial No Plate Fig 1 Serial Number and Locaticn The serial number is important information about the machine and it may be necessary to know it before obtaining the correct replacement part The serial number is located on the right side of loader subframe as shown The serial number should be recorded on the Warranty Registration form Figure 1 Replacement Parts Genuine BOLENS replacement parts only should be used to repair this machine BOLENS replace ment parts are available from the local BOLENS dealer To obtain prompt efficient service always remember to give the dealer the following information 1 Correct part description or part number 2 Model number of your machine 3 Serial number of your machine CHECKLISTS 1 Pre Delivery Checklist After the machine has been completely assembled and lubricated inspect it thorcughl gs ca main it is operating properly before delivering it to the customer The foilowing checklist is a rem orc unis te inspect Check off each item as it is found satisfactory or after proper adjustment is m cticns Check to make Sure Joader is completely assembled according to eee giru Chec
11. BE DOWN AND BUCKET CYLINDERS FULLY RETRACTED WHEN CHECKING FLUID LEVEL Aw CAUTION Add recommended rear wheal ballast and or rear counter weight for stability Move wheels to widest setting i to increase stability i N w Move and turn tractor at low 4 speeds gt In transport carry the load low g Lower loader to the ground i when parked 6 Before servicing or adjusting equipment E lower loader to the ground i shut off engine N Relieve hydraulic pressure before disconnecting oil lines Observe safety recommend ations in Loader Operations Manual 595 2001 30 1 Only gusiifiou lt i have read undarsta i ha safety pressuvions in th i Operators Menuai shouid oper ia ate the tractor loader Use of front snd loader for hand ling arge heavy objects such as large baies ogs oil drums atc is not racommendad Handling targe heavy objects i can be extremely dangerous due to N danger of roiling tractor over edanger of upanding tractor edanger of the object roiling or sliding down the loader I arms onto the operator If you must perform this sort of work protect yourseif by e never lifing higher than necessary to clear the ground when moving bailast tractor rear end to compensate for load moving slowly and carefully avoiding rough terrain enaver lift objects that are
12. Bucket Support the Cylinders to prevent excessive strain on hydraulic hoses in a position that will allow the Cylinders to be completely Extended SERVICE Hydraulic Cylinder Leakage Tesi Rod Seal Leakage Test Start tractor and Retract Cylinders completely Continue to hold Control Valve Lever in position to Retract Cylinders and check for evidence of oil leakage past the Rod Seal External Leakage Note On cylinders that have been in service Rod Seal leakage is usually indicated by accumulation of dirt oil at rod end of Cylinder Body if leakage is evident the cylinder s should be removed and disassembled for inspection and repair Note Inspect Cylinder Rod for pitting deterioration or damage to the chrome finish Any excessive damage to the chrome finish reduces the ability of the Rod Seal to seal properly If Rod Seal tests are satisfactory proceed to Piston Seal Assembly Leakage Test Piston Seal Leakage Tesi With cylinders in the fully Retractec positian and tractor shut off disconnect the wWwdraul s lines from the base end of cylinders gt gt hydraulic hese from the cylinder base to a container to catch oil during leakage s Start tractor and place Loader Cents aiva Lever in the position to Retract Syilr Hoid Check for oil leakage from base enc cylinders port of A constant dripping or very slight flow of cil is normal If a steady flow o
13. Model 14066 Owner Operaior Manual FRONT END LOADER e Safety e Operation e Maintenance For Tractors 5117H 9118HS 9120H 13060 13061 13062 13063 FORM 1768332 7 93 LE OF CONTENTS General Information Checklists Predelivery Checklist Delivery Checklist IIR0J IR Beginning Each Season Checklist 3 d Bo BS RS PO o 5 53 y ia Mi Sai iy LL uL te Product Gira DiC Sr TL LL Safety Precautions mmm I LL Loader Specifications m m n o o Material Bucket Canacities Lubrication and Maintenance Lubrication Chart ___________ ___UWXU s_ as Tractor Preparation LL Approved Tractors H ___________ I II Tractor Tires __________ BB Rear Counter Weight Front Counter Weight Operation Precautionary Notes Cold Weather Operation Loader Hydraulic Controls Loading Transporting Material Unloading Scraping Backfilling Backgrading Controlled Rate of Loader Functions Loader Removal and Installation Removal of Loader Installation Storage Service _______ AAA LL LL Hydraulic Cylinder I T III Hydraulic Cylinder Leakage Test mmm m m mm mm Control Valve m a LL Relief Valve Test Adjustment
14. Shut Tractor off engace parking Drake Disconnect hydraulic lines from Controli Valve Cap IN and RETURN lines to prevent con tamination of hydraulic system Remove control valve mounting capscrews Disassembly Refer to Control Valve illustration for component identification Control Levers and Connections Remove Quick Disconnect Couplings and Adap tor Fittings Plug all ports and thoroughly clean Control Vaive Disconnect control lever linkage from valve and remove levers Load Check Poppets Unscrew Load Check Poppet Plugs and remove Load Check Poppets and Springs Relief Valve Unscrew Relief Valve Cap followed by Adjust ment Screw and remove Relief Valve Spring Ball retainer and Ball Valve Spools Prior to removal mark Valve Spools to ensure they can be identified for installation in the same spool bores from which they were removed Bucket Cylinder Spco Remove Valve Spoci End Cap pS FNS anc pull Valve Spoc froin Var i ipul aut from spring end of s aoc gren Lift Cylinder Spool Fics Remove the Detent Cac Pigs S Soo ig and Gals and remove the two Sestent Gas nc iting screws Puil Vaive Spool from Vaiv ve Er23y pull out from spring end of spool If spool centering springs require repiacement remove as follows Bucket Cylinder Spool Remove spring retainer mounting screw from end of Vaive Spooi Lift Cylinder Spool Float Unscrew Detent Spool from Valve Spoo
15. area causing severe injury or death Load must be kept level A DANGER Avoid any overhead wires or obstacles when loader is raised to avoid damage or possible death by electrocution Scraping 70 4 When scraping the Float position should be utilized to maintain the bucket firmly on the ground and at the same time allow the bucket to follow ground contours The bucket should be positioned level to the ground during Scraping operations OPEA ATION Backfilling Backgrading When Backfilling or Backgrading position the bucket so it is level on the ground Do not dump material from bucket following each pass as additional weight of material in bucket will assist in Backgrading and increases loader effi ciency during Backfiliing Controlled Rate of Loader Funciicn By Feathering the Control Lever reduced it is important to utilize this operational practice operational speeds can be controlled This ac when lowering Loader Boom when the Bucket is tion controls the position of the Valve Spool in loaded with material the Valve Body and regulates flow of oil to from cylinders Single Lever Control 70 5 REMOVAL OF LOADER Select a levei place to remove loader Lower Loader and position Bucket flat on ground Shut Tractor off and engage parking brake Shift Loader Hydraulic Vaive into all modes to completely relieve hydraulic sressure in Loader riydraul
16. as specified in the Operation and Safety Instructions 3 Misuse accidents or normal wear DISCLAIMER OF CONSEQUENTIAL DAMAGES GARDEN WAY INC SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OR EXPENSE OF ANY KIND INCLUDING BUT NOT LIMITED TO COST OF EQUIPMENT RENTAL LOSS OF PROFITS OR COST OF HIRING SERVICES TO PERFORM TASKS NORMALLY PERFORMED BY THE EQUIPMENT LIMITATION OF IMPLIED WARRANTIES ANY IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO A PERIOD OF THREE YEARS 1 YEAR IF PRODUCT IS PURCHASED FOR COMMERCIAL INSTITUTIONAL INDUSTRIAL RENTAL OR DEMONSTRATOR USE FROM THE DATE OF SALE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATIONS ON HOW LONG IMPLIED WARRANTY LASTS THEREFORE THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOu This warranty gives you specific legal rights and you may also have other rights which vary from state to state For warranty information GARDEN WAY INCORPORATED 102 amp 9th Ave Troy NY 12180 GARDEN WAY INCORPORATED 215 South Park Street Port Washington Wisconsin 53074 1993 GARDENWAY INC PRINTED IN THE U S A
17. ce Plate missing in stalled upside down or orifice hole size is in correct 100 4 TROUBLE SHOOTING CORRECTION Cc heck Cyiinders for leakage s described under Cylinder eakage Tests m w Replace Control Valve and ra ao Determine origin of binding and repair Replace Cantering Spring Refer to Vaive Service pro cedure Disassemble valve for inspec tion and repair Refer to Valve Service procedure Tighten loose connection Check for origin of oil leak and replace defective part Replace defective O rings Replace Control Valve Perform Cylinder Leakage Test for Rod Packing Set as described under Cylinder Leakage Tests Check Orifice Plate for correct installation etc PROBLEI Hydraulic Pump Capacity inadequate Lift Cylinder Rods Bend when Lift Cylinders extended Bucket Cylinder Rods Bend when Bucket cylinders extended Bucket Cutting Edge Wear is Uneven Side to Side Bucket Cutting Edge Wear Rate is Excessive Wear rate is even across full width of bucket on concrete Note Extensive use of bucket on concrete asphalt surfaces will accelerate wear rate of bucket cutting edge POSSIBLE CAUSE Cold Hydraulic Fluid Engine R P M too slow Low hydraulic fluid suppiy Hydraulic Hose Restriction Hydraulic Pump defective Excessive shock load on Lift during transport Back grading or dozing with bucket cylinders extended Bucket is not levei t
18. ean hydraulic oil prior to in stallation 90 7 Vaive Spoois Assembie Spooi Return Springs on if they were removed previ Snert Sz ag used on Standard Sone Long Spring used cn Float Socci aive Spools fa Coat Valve Socols with clean hydraulic oil and carefully instaii in Valve Boay Install End Cap and Deient Cap mounting screws Note 1 Extreme care should be taken during Valve Spool installations to ensure O Rings ars not damaged 2 Float Valve Spool is installed in Valve Body adjacent to Relief Valve Following Detent Cap installation install Detent Balls Springs and Caps Load Check Poppets Coat Load Check Poppets with clean hydraulic oil and place in Valve Body followed by Load Check Springs and Plugs Note New O Rings should be installed on Plugs SERVICE Control Valve Control Lever and Hydraulic Connections Install Control linkage as illustrated Fig 14 install Adaptor Fittings and Quick Disconnect Couplers Note 1 Inspect Adaptor Fitting O Rings and replace if required 2 Color Code Rings should be installed to correspond with Color Code Rings on Hydraulic Hoses that connect to the Con trol Valve 90 8 installation Mount Control Valve on Valve Stanc Reconnect hydraulic noses to they were removec Note 4 Refer to Hydraulic System Diagram to check that nydra 2 tions are correct 2 Relief Valve Setting shouid 5e adjusted im
19. f oil is evident ex cessive wear or damage of the Piston Seal is in dicated and the cylinder s should be removed and disassembled for inspection and repair If Piston Seal Leakage Test in Retract position indicates Piston Seal is satisfactory reinstall hydraulic hoses and fully extend cylinders to per form test in Extend position With cylinders in the fully Extended position and tractor shut off disconnect the hydraulic lines from the rod end of cylinders Route a hydraulic hose from the cylinder rod end ports to a container to catch oil during leakage test Start tractor and place Loader Control Valve Lever in the position to Extend Cylinders and Hold Check for oil leakage from rod end port of cylinders A constant dripping or very slight flow of oil is normal if a steady flow of oil is evident ex cessive wear or damage of the Piston Seal is in dicated and the cylinder s should be removed and disassembled for inspection and repair SERVICE Controi Vaive AN Detsnt Ficat S Repair Kit 3 x E gn S co Orifice Plate A od Load Check Repair Kit Plug inciudes O ring Relief Valve Repair Kit oh Control Valve Plug Power Beyond Repair Kit Fig 13 90 5 SERVICE Control Vaive Control Valve Removal Prior to removing control vaive ensure loader is on the ground and all hydraulic lines are relieved of oil pressure
20. from rod l 90 1 inspection Clean all parts thoroughly Inspect Cylinca Body for evidence of scoring and piting Replacs Cylinder Body excessive pit ting scoring is 2vident Inspect Cylinder Rod for iiencs of siting or plating deterioration throu gt the secticn of the rod that sontac s the Rec 3 1 Inspect Sylinder Rod and Sody End Eyes for evidence of excessive wear Inspect Cylinder Gland and piston Replace any components that exhibit excessive wear or damage It is recommended that ail Cylinder Seais be replaced during Cylinder Assembiy Cylinder Assembly Clean and dry all Cylinder components thoroughly install seals on Piston and Gland Place Gland Assembly on Cylinder Rod Note Refer to illustration for reference to component orientation and sequence Assemble Piston Assembly on Cylinder Rod referring to illustration for reference to compo nent orientation and sequence Install locknut and torque to 75 ft Ibs SERVICE gt hydraulic oil and 3d in a bench vise od Assembly in taken to ensure uring installation with clean hydraulic er Body to align re cutout section in Rotate G located in retaining wire groove is the Sylinder Body cutout Install he end vo retaining wire in hole and rotate Glar pull retaining wire into place in Gland Cylinder Body grooves Important Rotate Gland to a final position that ends of the retaining wire approximete a
21. h any exposec turfs with grease Wipe ary sucricate with an oii 5 Tighten any bolts that save loosened and make sure all pins and retainers are in place 6 Start tractor and operate loader to make sure it is operating properly and all the hoses are pro perly connected 7 Check hydraulic fluid leve ar fill as required 8 Make sure hydraulic hoses lines and fittings are in good shape and not leaking Replace or repair as required 9 Review Safety Precautions and Operation sections of manual SERVICE Hydraulic Cylinder Service General Cylinder ports should be capped at all times when hydraulic hoses are disconnected to pre vent contamination Cylinder Disassembly Refer to illustration for component identification Drain all oil from cylinder and retract rod fully Secure Cylinder Assembly in a bench vise by the cylinder body and eye Remove Gland Assembly as follows Rotate Gland until end of Retaining Wire is visi ble in cutout section of Cylinder Body Pry Retaining Wire up and rotate Gland in reverse direction and continue rotating to feed Retaining Wire out of Cylinder Body Pull Cylinder Rod Assembly out of Cylinder Body Gland will come out of Cylinder Body along with Cylinder Rod Assembly Secure the Cylinder Rod Assembly in a bench vise by the end eye of the rod Do not clamp on the chromed finish section of the rod Remove Piston Assembly locknut and pull Piston Assembly
22. heck for Seepage Check Replace if Missing Check Re torque if necessary Check Visually Re torque 50 2 SERVICE INTERVAL Daiiy 10 Hours Annually Weekly 50 Hours Daily i0 Hours Daily 10 Hours Daily 10 Hours Daily 10 Hours Weekly 50 Hours Weekly 50 Hours Every 200 Hours Fig 4 TRACTOR PRESENT LO Approved Tractors IMPORTANT To prevent structural Damage all Tractors must be equipped with Heavy Duty Front Axle Order Front Axle Kit 51911 for all Tractors below Serial Numbers listed 5117H 030010 5720H 0300107 5118HS 0200101 Tractor Tires IMPORTANT Tractor must be equipped with 4 ply Tires con tained in Loader package Inflate Tires to 28 psi Front tires should be maintained at correct infla tion to maintain normal tire profile with added weight of loader and material Rear tires must be maintained at equal pressure within the recommended tire inflation range Unequal rear tire inflation can prevent loader at tachment from contacting the ground across its full width Rear Counterweight AX caution Add recommended rear wheel ballast for increased stability S The use of adequate counterweight to counter balance for maximum loader capacity is required for safe loader operation Weight added to rear of the tractor provides bet ter traction and easier more efficient toader operation Additional counterweight requirements will vary with loader attachments and equipment appl
23. i turn beyond the cutout section bearer Bedy stail dust plugs in Cylinder ports Hydraulic Cylinder Assembly Body Assembly Locknut Piston Backup Piston Seal Backup Grease Fitting O Ring Gland Backup Se Retaining Wire Rod Seal Gland Rod Wiper Rod Assembly 90 2 Fig 11 SERVICE Hydraulic Cylinder Leakage Tes i Piston Seal X ie Sy Rod Seal CAN x i ac ae ok SY NE a N AS LN NNN AN N_A ap VY Z ET TT TET RII AET t Gland Fig 12 General A CAUTION Safety glasses shouid be worn when performing Cylinder Leakage Tests When performing Cylinder Leakage Tests the tractor engine should be operating at mid R P M to ensure the hydraulic system reaches the Relief Valve Setting During tests the System Relief Valve governing maximum pressure to the Loader Cylinders will be Open system is at Relief Valve Setting Note Do not maintain Hydraulic System at Relief Valve Setting pressure for more than 20 second inter vals to prevent overheating hydraulic system 90 3 The Test Procedures outlined enable the cylinders to be checke for Rod Seal Leakage External Leakage and Piston Seal Leakage in both directicns Interna Leakage Test Procedure Lower Loader to the ground shut tractor off and disconnect cylinders as follows Lift Cylinder Test disconnect from Subframe Rod End Bucket Cylinder Test Rod End disconnect from
24. ic Fluid Check coupler s Repair or replace Check orifice plate installation Check hoses and tubelines for evidence of restriction Check cylinders for leakage as described in Service Section under Cylinder Leakage Tests Check Relief Valve Setting as described under Relief Valve Test Replace Control Valve and recheck operation Refer to Hydraulic Pump Capacity Inadequate Aeration of Hydraulic Fluid generally indi cated by foamy appearance of fluid System Relief Vaive Squeals TROUBLE SHOOTING POSSIBLE CAUSE Engine R P M too siow Excessive Load Material weight exceeds specified Loader capacity Relief Vaive setting below specifications Lift Cylinder Piston Assembly Leakage Control Valve leaking internally Hydraulic Pump defective Low Hydraulic Fluid Level Air leaking into suction side of hydraulic pump Hydraulic Fluid Foaming due to improper hydraulic oil usage Cold Hydraulic Fluid Excessive Load in Bucket Weight exceeds specified Loader capacity Relief Valve Setting below specifications Hydraulic hose tubeline or Quick Disconnect Coupler Restriction 100 3 CORRECTION Increase Engine RAM Reduce load Check Relief Valve Setting as described uncer Relief Vaive Test Check cylinders for isakage as described in Service Section under Cylinder L m sakage Tests Replace Contro Vaive and recheck operation Refer to Hydraul
25. ic Pump Capacity inadequate Check and refill Hydraulic System to proper levei See Lubrication and Maintenance Section Check for loose or defective connections between reservoir and hydraulic pump Replace Hydraulic Fluid and Filter Allow hydraulic fluid to warm up to operating temperature Reduce loads Check Relief Valve Setting as described under Relief Valve Test Check for evidence of re striction in hydraulic oil flow Repair or replace defective componenti s PROBLEM Loader Drops with Con trol Valve Spooi in Centered Position No external oil leakage evident Note A gradual drop over an extended period is a normal condition Control Vaive Spool s Will Not Return Position to Centered Position External Hydraulic Fluid Leakage Loader Boom Drops Too Fast when Control Lever positioned to down Note Control Lever should be Feathered when lowering loader boom with loaded bucket to control drop rate POSSIBLE CAUSE Cylinder Piston Assembly Leakage Control Valve Internal Leakage Contro Lever Linkage Binding Control Valve Spool Centering Spring broken Control Valve Spool binding in Valve Body Spool bore Loose hydraulic connection Defective hydraulic hose tubeline adaptor fitting or adaptor fitting O ring Control Vaive O rings defective Control Valve Spool or Body damaged or worn Cylinder Rod Packing Set leakage Orifi
26. ic Sysem Remove Hinge Assemblies Start Tractor and adjust Engine Speed to idle CAUTION During Loader removal Loader Pressure and Return Hoses must be clear to ex tend forward with Loader Ensure Hydraulic Hoses are kept in a position to prevent them from interfering with adjacent Tractor Mower components Slowly extend Lift Cylinders to raise Subframe out of Rear Mount Slowly back Tractor out of Loader Extend Lift Cylinders as necessary to clear front tires Note Loader may need to be lifted off ground approximately 2 to allow tractor to clear When Front Mount contacts Parking Stop ex tend Lift Cylinders until Loader Subframe Pump Guard rests firmly on ground Shut Tractor off and engage Parking Brake Remove Hydraulic Pump retaining hardware and disengage from Tractor Front PTO Position Hydraulic Pump on Loader for storage 80 1 EMOVAL AND INSTA INSTALLATION Advance Tractor int ic der unt ront Mount contacts Subftrame Arms Shut Tractor off and 2 gt 198 parki J brake Engage Hydraulics Puss gt Tractor Front PTO Start Tractor and adjust Engine Sr aed to idle Retraci Lift Cylinders and advance Tractor slow ly When Front Mour is secure in Retaining Hcoks retract Lift Cyiinders to place Loac ar Subirame in Rear Mounts Shut Tractor off and sngage parking brake Shift Loader Hydraulic Valve into all modes to completely relieve hydraulic pressure in Loader Hydraulic Sys
27. ica tions Additional weight should be added by installa tion of Rear Wheel Weights Kit 3092 provides minimum weight requirements 60 1 Froni Couniernve 2 when tractor is be tion Peet TS the rated load OPERATION Precautionary Notes Do not lower the edge of an attachment too iow for loading Keep the bottom of the attachment level with the ground when loading Sooortant 5o not use an attachment for pushing down material with the cylinders partially extended Damage to the cviinders may ssult important l Make sure that bucket is contacting the stops before leveling or scraping with it important Operation with front tractor wheels off the ground is not recommended Position vehicles to be loaded as near the pile as possible and in such a direction as to minimize the amount of tractor turning required to dump Do not lower the loader with the tractor engine shut off Keep the unit clean and perform regular service Observe safety pointers whenever cleaning ser vicing or lubricating We urge you to follow this advice 1 Read and understand this manual as Well as the tractor Operator s Manual 2 Remember and observe the Safety Precau tions particularly the Don ts brought to your attention in this manual the tractor manual and on the machinery itself 3 Use good common sense in the everyday operation of this unit Safety recommendations can never be all incl
28. k all bolts to make sure they are tightened to specified toraue value Inspect and if necessary lubricate all lubrication points Make sure all fittings are in piace and taking grease properly Inspect all hydraulic hoses lines and fittings to make sure they are insialled trooerly and not leaking Make sure hydraulic hoses are properly routed and will not be damaged when the loader is rais ed or lowered Start tractor raise and lower loader and operate bucket cylinders and make sure unit is operating properly Check hydraulic fluid level Add hydraulic fluid as required Use Type A Hydraulic Fluid or Equivalent inflate tractor s front tires to 28 psi 2 Delivery Checklist Explain warranty then complete warranty registration forms listing the serial number of the loader Dealer and customer must sign forms Explain importance of proper lubrication and indicate all lubrication points on the loader 20 1 CHECKLISTS Delivery Checklist Contd Advise customer of safety hazards involved when operating the tractor and loac sier to Safety Precautions section of manual Advise customer of the importance of adding proper rear wheel weights Kit No 30502 to rear wheels of tractor to compensate for additional weight being added to rent and when loader is installed Kit No 30902 provides only the minimum rear wheel weigri requirements Explain proper operation of the loader and its controls to the customer
29. l Remove the four Valve Spool O Rings from the valve body Thoroughly clean all parts Inspection Remove any nicks or burrs from valve com ponents and inspect for evidence of excessive wear Note If internal leakage with the Valve Spools in the spring centered position has been experienced Valve Body and or Valve Spool wear is indicated if this condition exists the Control Valve Assembly must be replaced SERVIC Control Valve Inse Valve Body for wear or da inspect sail Seat for wear or damage Inspect Lift ve Spool Detent Spool for excessi atent area Note If Float Spoo gt t stay in Detent position or tends to be tent Spool w indicated and ed tto get into Detent De ior weak Detent Springs are ected parts should be replac Inspect Valve Scol Return Springs for evidence of wear damage Note TEF if Valve Spool s was not centering properly and Valve Spool slides freely in Valve Body a weak or broken return spring is indicated Inspect Relief Valve Spring for damage and distortion Inspect Load Check Poppets and Poppet Return Springs for damage and distortion It is recommended that all O Rings be replaced during Valve Service Assembly Refer to Assembly illustration for reference to Parts Thoroughly clean and dry all parts Carefully install the four O Rings in the Valve Body Spool bore O Ring grooves Note Coat O Rings with cl
30. l cecal is supplied with the Loader and is to be applied on the Top Horizontal Surface of the Bucket Level Indicator 120 1 pa Level Decl et i HITED WARRANTY s I PRODUCTS COVERED This warranty applies to all Bolens branded equipment Troy Bilt branded tractors muich mowers sno gas and electric sprayers and all W W Grinder branded equipment to include their attachmuns anc or aces all Troy Bilt branded equipment sold as a commercial institutional industrial rental or demonstrator angiiestic il PRODUCT WARRANTY NON COMMERCIAL RESIDENTIAL THREE YEAR LIMITED WARRANTY Ail new Bolens Troy Bilt and W W Grinder equipment specified above is warranted cy Garden Way inc o tha original retail purchaser only to be free from detects in material and workmanship under normai use and secs fet period of three 3 years from date of purchase Engines manufactured by Briggs amp Stratton Kohler and Tecumseh or transmissions Manu ile S be warranted for this three year warranty period through the authorized repair stations 3 EXCLUSIONS The following items are not covered under the second and third year of this sxiendad nome gt gt imited i warranty Belts Hoses Seats Batteries Blades Knives Tines Fitters Tires Wheels Paint anc Aosearance ite ah zat Bulbs and similar items which are normally replaced through periodic maintenance li PRODUCT WARRANTY COMMERCIAL
31. luid has warmed to operating temperatures OPERATION Loader Hydraulic Controis Loader Hydraulics are activated by Engaging Tractor front P T O The P T O switch is located on the RH side of the Instrument Panel The loader Hydraulic Valve Features Single Lever Control Refer to figure 5 for reference to Loader Control Functions The Loader Hydraulic Vaive Lift Cylinder circuit incorporates a Float position which allows the loader bucket to follow ground contours The Float position is engaged by shifting the con trol lever forward into Detent The Loader Hydraulic Valve will remain in Detent until the operator pulls the control lever out of the De tent position Refer to Scraping operation for recommended use of Float position 70 2 Single Lever Control Aaa AS na DEE SOREL EE es seadh Fig 5 PERATION Loading Drive straight into pile with the bucket cutting edge level with the ground in order to prevent possibility of damaging tractor or loader Do not ram into pile at high speed Do not attempt to turn tractor while loading As the bucket begins to fill with material gradually roll the bucket back and raise the loader to increase Fill capacity This pro cedure also results in the material being remov ed in layers from the top for maximum loading ef ficiency When the bucket is full raise joader so that the bucket is clear of material and
32. naers in Retracted pes cns Drain and replace Hydraulic fluid and Filter every 300 hrs annually Use Hydraulic Fluid Reservoir Return port to Drain Reservoir Service interval should be shortened if loader is operated in adverse conditions Use Type A Hydraulic Fluid or Equivalent Grease all loader pivot points caily 10 hours Refer to Tractor Operators Manual for lubricant recommendations Inspect hydraulic hoses connections control valve and cylinders for evidence of leakage Tractor Tire inflation should be checked at recommended intervals to ensure tire inflation is to specifications Front 28 psi Rear 12 psi Unequal rear tire inflation can result in bucket not being level to the ground Front tires should be maintained at maximum recommended inflation to maintain normal tire profile with added weight of loader material Acaution The tractor loader should only be operated with all safety equipment properly in stalled LUBRICATION AND MAINTENANCE Siang Luji 10 Lubricate with pressure gun using grease as recommended in Tractor Operators Manual ITEM Hydraulic System Oil Level Hydraulic System Oil Filter Tire Inflation Loader Pivot Points Loader Hydraulic Lines Hoses Connections Lift and Bucket Cylinder Rod Packings Pivot Pin Clips Subframe Hinge Clamping Bolts Loader Mount Hardware SERVICE Check Replace Check Lubricate Check for Leaks Wear C
33. nless it is securely blocked in position Accidental movement of control lever or leak in hydraulic system could cause loader to drop resulting in severe injury Do not lift or carry personne on a loader or attachment a slip or fall could cause bodily injury Load on raised bucket or fork can roll back onto operator area causing serious injury or death When loading material from a large pile remove the top level first to prevent material from falling caus ing death personai injury or damage to equipment Remove Mid Mount Mower if equipped during loader operation 30 3 SAFETY Safety Precautions Do not carry round bales on loader unless loader is equipped with a restraining device to prevent gale froin rolling down loader frame resulting in severe injury or death to the operator Always use adequate lights or safety warnings when transporting machine on pubiic roads and ato ca Be certain SMV embiem is visibie Check with your iocal law enforcemeri agencies for scectific r quirements Avoid loose fill rocks and holes they can be dangerous for loader operatien sr movemer t Be careful when working on inclines Allow for the loader length when making turns Before disconnecting hydraulic lines relieve all hydraulic pressure Escaping hydraulic oii under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping fluid obtain medical treatment immediately Do
34. not operate the loader if the fittings are leaking or if the hoses are damaged A sudden line burst would cause the loader to drop suddenly causing injury to personnel or damage to the tractor or loader A loader bucket or attachment should be transported in a low position at slow ground speeds especially if the ground is irregular Make turns slowly and use the tractor brakes cautiously A fuil bucket in the raised position alters the center of gravity location of the machine and increases the possibility of mishaps Lower all components before leaving the machine All attachments should be in closed position and Bucket resting on Ground Elevated components can fall and cause serious injury Never work beneath a raised loader unless it is securely blocked with a safety bar A suitable safety bar can be fabricated following dimensions in the illustration below Fig 3 LOADER SPECIFICATIONS Specifications shown are based on ASAE Stan dards Specifications may vary with tractor model front axie configurations tire size op tions and type of Attachment Front TICS cass sacsceasia aaa dag autzzerepvanhnostonpsacorboteptotinbnabcbsacedsoeagulsaantiemnabiialalaaluctacacaeisinge 16 6 50 4 ply 28 psi PROM eT BOS E Sie ali E EE E ES E E cate Ashe ch coun 23 10 50 12 psi Maximum Lift Heg eecceesesssscsseccesseseseee Clearance with Bucket Dumped pisses Reach at Maximum Height Maximum Dump Angle
35. o ground Incorrect Operational practices Excessive down pressure placed on Bucket when being used on hard abrasive surfaces Bucket Wear Pads worn 100 5 CORRECTION Allow hydrauiic tuid Te Roun up to operating ternceralore increase Engine A P Refer to Lubrication and Maintenance Section Check for evidence of fe striction in hydraulic hoses Replace hydraulic pump if determined to be defective Replace defective parts Review and observe proper and safe operational practices Replace defective parts Review and observe proper and safe operational practices Check Rear Tire inflation and adjust pressures to level bucket to ground Refer to Operation Scraping section for correct operating procedures Utilize Float position Replace wear pads amp 23 83 Oro Bucket Cylinder Extend Bucket Cylinder Retract Lift Cylinder Extend Lift Cylinder Retract Quick Disconnect Coupler Bucket Cylinders cat Lift Cylinders Loader Control Valve Hydraulic ees 3421 IN Fig 16 110 1 IMENTS AND AC SSORIES fully rolled high ar joading and more sumped 1 which creates its own Qremium quality beveiled ongevity of bucket service wear and distortion A fixad BockeT Level indicator is incorporated on the Matemal Bucket Attachment It enables the operator to position the Bucket Attachment level on the ground quickly and easily A Leve
36. tem Install Hinge Assembiies on Loader Subframe JADER REMOVAL AND IN ALLATIOM Fig 7 Fig 8 80 2 IR REMOVAL AND INSTALLATION Fig 10 80 3 STORAGE End of Season 1 l loader is to be dismounted from the tractor during storage make sure parking area is on hard level ground Cap all hydraulic hoses to prevent contamination 2 Store loader in a dry sheltered area if possi ble 3 Thoroughly clean the loader of all ac cumulated dirt and grease 4 Completely lubricate the loader as specified in Lubrication section of manual 5 Using an oil soaked cloth lubricate all hydraulic cylinder rods to protect them from rust and corrosion 6 Repaint any areas where paint is worn or damaged 7 Wear areas on buckets or other attachments should be coated with grease to prevent rust or corrosion 8 Replace any Safety or Warning decals that are not readable due to wear or damage 9 Replace any damaged or worn parts A WARNING Do not allow children to play on or around the tractor or loader 80 4 Beginning of Seaton 1 Thoroughly clean the loader cf cumulated dirt and greasa 2 W removed from tractor fer sin wja IU ut loader per procedure in this manual 3 Completely luccicate the loader me tion section of ms uai Make sure thefittings are taking grease o csery 4 Ciean with sciver cas which nad been coe so with a clean cloth then soaked ciot
37. ting lines be sure to relieve all pressura 2 ore applying pressure to the system be sur ill connections are tight and that lines p 2s and hoses are not damaged Fluid escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than your hands to search for suspected leaks See a Doctor at once if injured by escaping fluid Serious infection or reaction can develop if cor rect medical treatment is not administered im mediately Akcinio Do not operate the loader if the fittings are leaking or if the hoses are damaged A sudden line burst could cause the Boom Assembly to drop suddenly causing damage to the tractor or loader or injury to personnel Ad caution Operate the loader from the trac tor seat only caution Do not stand or walk under a raised attachment Accidental movement of control iever or leak in hydraulic system could cause Boom Assembly to drop causing severe injury 50 1 N AND MAINTENAN Ca Refer to Lubrication ad tenancs Che for quick reference tc ain s ce Operati Figure 4 Check hydraulic system fluid le al Lower loz to ground and retrect bucket it Rem 3 _ Overflow plug loca on se facas o PH Loader upright Rss c sir li reservoir to Cyerlow Use Type A hydraulic fluic or equivalent Note When checking Hydra ic 2 ste Oil Leval t Loader aould os or th ground and buck c fui retraciec All Cyii
38. usive and you are responsi ble for watching out for and avoiding unsafe con ditions 4 Never exceed the limits of a piece of machinery If its ability to do a job or to do so safely is in question Don t Try It 5 Don t hurry the learning process or take the unit for granted Ease into it and become familiar with your new loader and tractor A CAUTION When lowering a heavy oad ease it dowr ward slowly Never cree loaded at tachment anc catch hydraulically sTapping a load after it has gained dowcware momentum places undue sirain on the unit ana may cause unneccesary damage to the loader actor or even worse personai injury A CAUTION Baiora discocnes ing hydraulic lines relieve all hvdrauiic pressure E2c ming hydraulic oi under oressure Cas hve sufficiant force to penetrate ihe skin causing Serious per sonal injury If in i by escaping nydrautic oil consult a physicia immediaiely CAUTION Do not operaie THe oader if the fittings are leaking or if the hests Ara damaged A sudden iine burs would cause ihe Boom Assembiy to drop suddenly causing damage to the tractor or loader or injury te personnel BEFORE OPERATING LUBRiCATE ALL MOV ING PARTS Cold Weather Operation To assure smooth operation in cold weather allow tractor to warm up SLOWLY cycle the loader and attachment several times to warm the fluid in the hydraulic system The icader may operate erratically until the hydraulic f
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