SunBear DL165H Operator Manual

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SUNBEAR HEAVY EQUIPMENT

DL165 Skid Steer Loader

Owner's

and

Operator's

Manual

PUBLICATION NO. 16500

SEPTEMBER, 2009

SUNBEAR HEAVY EQUIPMENT LIABILTY WARRANTY

THE WARRANTY IS THE ONLY OBLIGATION OF SUNBEAR HEAVY EQUIPMENT OR A SUNBEAR HEAVY EQUIPMENT DEALER TO THE PURCHASER OR ANYONE ELSE CONCERNING A PRODUCT. IT'S USE OR PERFORMANCE OR ITS LOSS OF USE OR FAILURE TO PERFORM. NEITHER SUNBEAR HEAVY EQUIPMENT NOR A IMPLIED REPRESENTATION, WARRANTY OR AGREEMENT CONCERNING A PRODUCT, NEITHER SUNBEAR HEAVY EQUIPMENT NOR A SUNBEAR HEAVY EQUIPMENT DEALER HAVE MADE OR WILL MAKE ANY REPRESENTATION, WARRANTY OR AGREEMENT CONCERNING A PRODUCT'S MERCHANTABILITY OR OTHER QUALITY, IT'S SUITABILITY FOR PURCHASER'S PURPOSE (EVEN IF A PURCHASER HAS INFORMED SUNBEAR HEAVY EQUIPMENT OR A SUNBEAR HEAVY EQUIPMENT DEALER OF THAT PURPOSE), IT'S DURABILITY, PERFORMANCE OR OTHER CONDITION.

EVEN IF SUNBEAR HEAVY EQUIPMENT OR A SUNBEAR HEAVY EQUIPMENT DEALER WAS ADVISED OF THE POSSIBILITY OF SUCH LOSS, NEITHER SUNBEAR HEAVY EQUIPMENT NOR A SUNBEAR HEAVY EQUIPMENT DEALER WILL BE LIABLE TO PURCHASER OR ANYONE ELSE FOR ANY INDIRECT, INCIDENTAL CONSEQUENTIAL, PUNITIVE, ECONOMIC, COMMERCIAL, OR SPECIAL LOSS WHICH IN ANY WAY ASSOCIATED WITH A PRODUCT. THIS INCLUDES ANY LOSS OF USE OR NON-PERFORMANCE OF A PRODUCT, ANY REPLACEMENT RENTAL OR ACQUISITION COST, ANY LOSS OF REVENUE OR PROFITS, ANY FAILURE TO REALIZE EXPECTED SAVINGS, ANY INTEREST COSTS, ANY IMPAIRMENT OF OTHER PERSON.

PURCHASER MAY NOT ATTEMPT TO ENLARGE ITS RIGHTS UNDER THE WARRANTY BY MAKING CLAIM, FOR INEMNITY, FOR BREACH OF CONTRACT, FOR BREACH OF COLLATERAL WARRANTY, FOR A TORT (INCLUDING NEGLIGENCE, MISREPRESENTATION OR STRICT LIABILITY) OR BY CLAIMING ANY OTHER CAUSE OF ACTION.

THE WARRANTY IS A CONDITION OF SALE OF THE PRODUCT TO THE PURCHSER AND WILL THEREFORE APPLY EVEN IF THE PURCHASER ALLEGES THAT THERE IS A TOTAL FAILURE OF THE PRODUCT.

WARRANTY DELIVERY: TWO (2) YEARS 1000HOURS (FOR ONLY SAMPLES).

N.B. Read and practice your Sunbear Heavy Equipment operating and servicing instructions.

Failure to do this may void the warranty.

PUBLICATION NO. 16500

SEPTEMBER, 2009

INDEX

1. SAFETY PRECAUTIONS

2. CONTROLS

2. 1 Instrument Panel

2. 2 Control Lever Handles

2. 3 Seat and Seat Belt

2. 4 Seat Bar

2. 5 Parking Brake

2. 6 Throttle Control

2. 7 Lift Arm Support

2. 8 Steering Control

2. 9 Auxiliary Controls

2. 10 Liftarm Control

2. 11 Quick - Tach

2. 12 Electrical Panel

3. OPERATION

3. 1 Starting Instructions

3. 2 Operating Procedure

3. 3 Filling From a Pile

3. 4 Digging with a Bucket

3. 5 Leveling and Backfilling

3. 6 Auxiliary Hydraulics

3. 7 Lifting

3. 8 Towing

3. 9 Securing and Transporting

3. 10 Lowering Lift Arms

3. 11 Accumulator

4. MAINTENANCE

4. 1 Preventive Maintenance Service Schedule

4. 2 Service Access

4. 3 Daily Service Checks

4. 4 50 Hour Service Check

4. 5 250 Hour Service Check

4. 6 Final Drive Maintenance

4. 7 Hydraulic / Hydrostatic System Maintenance

4. 8 Engine Maintenance

4. 9 Air Cleaner Maintenance

4. 10 Engine Cooling System

4. 11 Electrical System

4. 12 Tire Maintenance

4. 13 Trouble Shooting

4. 14 Hydraulic / Hydrostatic Circuit

4. 15 Special Tools

5. SPECIFICATIONS

5. 1 Loader Specifications

5. 2 Torque Specifications

5. 3 Decals

6. A TTACHMENTS AND BUCKETS

6. 1 SUNBEAR Approved Buckets and Attachments

WARNING

This warning indicates

hazards or unsafe

practices which COULD

result in severe personal

injury or death.

This warning indicates an

immediate hazard which

WILL result in severe

personal injury or death.

DANGER

Instructions are necessary

before operating or

servicing this machine.

Read the operators manual

and service decals on the

loader. Follow warnings and

instructions in this manual

when making repairs,

adjustments or servicing.

Check for correct operation

after adjustments and

repairs.

IMPORTANT

This notice shows

important procedures

which must be followed

to prevent damage to the

loader or attachment.

IMPORTANT

This warning indicates

hazards or unsafe

practices which COULD

result in minor personal

injury or product or

property damage.

CAUTION

FOREWORD

This book has been written to give the Owner / Operator necessary operating, servicing and preventative maintenance instructions on the loader. Read this manual completely and know the loader before operating or servicing it. Do not do any service procedures that are not in the Operator•s manual. Only service personnel that have had training in the service of this loader can do these service procedures.

Reference Information

Write the correct information for your loaders in the spaces below. Always use these numbers when referring to your loader.

Model No. Serial No. Dealer Name Address Phone

Throughout this manual the terms DANGER, WARNING and CAUTION are used to indicate the degree of hazard in terms of personal safety. These words will be used in conjunction with the Safety - Alert symbol, a triangle with an exclamation mark. Throughout this manual, the term IMPORTANT is used * To indicate that instructions are necessary before operating or servicing the

loader.

* To show important procedures which must be followed to prevent damage to

the loader or attachment.

1. SAFETY PRECAUTIONS

The following precautions are suggested to help prevent accidents.

A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. Read and take the following precautions before operating this loader to help prevent accidents. Equipment should be operated only by those who are responsible and instructed to do so.

1. Read this manual carefully before using the loader. Working with unfamiliar equipment can lead to accidents.

2. Do not allow anyone to ride on the loader with the operator.

3. Make sure the seat bar is installed and functioning at all times.

4. Never run the engine in a closed building without adequate ventilation, as the exhaust fumes can cause death.

5. Always fasten the seat belt around your waist before starting the engine. Never fasten the seat belt behind you.

6. Never attempt to start the engine while standing beside the unit unless as specified in this manual or under specific service and backhoe operation procedures. Start the engine only while sitting in the operator•s seat with the seat belt fastened around you. Always check to make certain that the seat cushion is secured to the frame.

7 Keep the operator•s area free of debris.

8. Never enter or leave the loader while the engine is running. Always lower the lift arms down against the frame, drop the attachment down to contact the ground, set the parking brake and shut off the engine prior to leaving the loader.

9. If the unit is equipped with a cab enclosure kit always close the door prior to operating the loader lift arms.

10. Do not operate the loader unless all safety equipment, shields, seat belt, seat bar, hydraulic controls, parking brake, operator guard, and lift arm support are working properly, as well as all safety and instruction decals are in place.

OPERATING THE LOADER

1. Always drive the loader at speeds compatible with safety, especially when operating over rough ground, crossing ditches or when turning.

2. Avoid jerky turns, starts, stops, or reverses.

3. Use care when operating on steep grades to maintain proper stability.

4. Do not turn the loader while the lift arms are in the raised position.

5. Be careful when driving through door openings or under overhead objects. Always make sure there is sufficient clearance for the operator•s guard.

6. When travelling on public roads, know the local rules and regulations and make sure your loader is equipped with the proper safety equipment.

7. Always be sure of water, gas, sewage and electrical line locations before you start to dig.

8. Watch out for overhead and underground high-voltage electrical lines when operating the loader.

9. Park the loader on level ground where possible. If the loader is to be parked on an incline, always lower the attachment so it contacts the ground, set the parking brake and block the wheels.

10. Do not leave the loader when it is in motion.

11. Do not dismount from the loader and leave the loader lift arms raised, unless following specific service procedures. Always lower the lift arms down against the frame and drop the attachment down to contact the ground.

12. Always be watchful of bystanders when operating the loader.

13. Always carry the attachment low for maximum stability and visibility.

14. Exercise extreme caution when operating the loader with a raised attachment.

15. Never attempt to lift loads in excess of loader capacity.

16. Check that control lever functions are locked before getting out of the operator•s seat.

17. Keep both hands on the control levers while the loader is in motion.

MAINTENANCE

1. Stop the engine before performing any service on the loader.

2. Never refuel the loader while smoking or with the engine hot or running.

3. Replace all missing, illegible or damaged safety and warning decals. See Section 5.3 for list.

4. Do not modify or alter, or permit anyone to modify or alter this loader or any of its components or any loader function.

5. Do not bypass the safety system. Consult your SUNBEAR Equipment Dealer if your safety controls are malfunctioning.

6. Do not make mechanical adjustments while the loader is in motion or when the engine is running. However, if minor engine adjustments must be made, securely block the loader with the wheels clear of the ground, and use extreme caution.

7. Do not attempt to repair or tighten hydraulic hoses when the system is under pressure, when the engine is running or when the lift arms are raised.

8. Do not get under the attachment or lift arms or reach through the lift arms when they are raised.

9. Never attach the chains or ropes to the operator•s guard for pulling purposes, as the loader can tip over.

10. Whenever servicing or replacing pins in cylinder ends, buckets,

etc., always use a brass drift and a hammer. Failure to do so could result in injury from flying metal fragments.

11. Cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while system is hot. Always turn cap slowly to the first stop and allow the pressure to escape before removing the cap entirely.

12. Keep the operator area free from debris.

13. For lifting and towing instructions, refer to Sections 3.7 and 3.8 of this manual.

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

To prevent personal

injury do not operate the

loader without lowering the safety bar, fastening

the seat belt and keeping

feet on the cab floor.

WARNING

This engine is equipped with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

IMPORTANT

C-359

1. SAFETY PRECAUTIONS

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

START SAFELY

1. Sit in the operator's seat and adjust it so you can operate all of the controls properly.

2. Adjust the seat and fasten the seat belt. Cycle the controls to make sure they are in the locked or neutral position. Lower the seat bar.

3. Know the exact starting procedure for your machine. See Section 3 for the manufacturer•s instructions for starting.

PARK SAFELY

Select level ground whenever possible. If you must park on a slope or incline, position the machine at right angles to the slope. Lower the attachment to the ground, engage the parking brake and block the wheels (C359).

C - 360

2. 1 Instrument Panel

2. 2 Control Lever Handles

2. 3 Seat and Seat Belt

2. 4 Seat Bar

2. 5 Parking Brake

2. 6 Throttle Control

2. 7 Lift Arm Support

2. 8 Steering Control

2. 9 Auxiliary Controls

2. 10 Liftarm Control

2. 11 Quick-Tach

2. 12 Electrical Panel

2. CONTROLS

1. Left Signal Indicator Light: This light will

illuminate when the operator uses the optional left signal. (Optional)

2. Auxiliary Front Indicator Light: This light will illuminate when the loader auxiliary hydraulic front switch is turned on. Light does not operate when lever switch is depressed.

3. Hi-Flow Hydraulics Indicator: This light will illuminate when the loader hi-flow hydraulics are in use. (Optional)

4. Work Lights (Up) Indicator: The light will illuminate when the loader work lights are turned on. This will serve as a reminder to turn them OFF when the loader is not in use.

5. Right Signal Indicator Light: This light will illuminate when the operator uses the optional right signal. (Optional)

6. Hydraulic Oil Temperature Indicator: This light will illuminate when the oil temperature has exceeded recommended levels. Shut off the engine immediately and determine the cause.

7. Brake Light Indicator: The brake light will illuminate when the parking brake is engaged.

8. Seat Belt Indicator Light: This light will illuminate when the seat belt is unfastened.

9. Work Lights (Down) Indicator:

10. This light will

11.

The light will illuminate when the loader work lights are turned on. This will serve as a reminder to turn them OFF when the loader is not in use.

14. Air Cleaner Indicator Light: This light will illuminate when there is an obstruction in the intake or when the air filter needs servicing. If this light illuminates, stop the engine and service the cleaner.

2. CONTROLS

2.1 INSTRUMENT PANEL

K5250A

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

This engine is equipped with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

IMPORTANT

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17

000032󰼿H

1/10

½HOUR󰼿METER

0 FULL

21 22

18 19 20

12. Coolant Temperature Indicator Light: This light will illuminate if there is a rise in engine temperature. If this occurs, shut of

f the engine immediately and determine

the cause.

13. Alternator Indicator Light: This light will illuminate when the alternator is not producing sufficient current.

15. Pre-heat Indicator Light: This light will illuminate when the ignition key is turned counter clockwise to activate the engine glow plugs.

16. Headlight Switch: This is a toggle switch. Push up to turn the dipped beam lights on. These lights are located on the front of the loader.

17. Auxiliary Hydraulics Front Switch: This switch is a toggle switch. Push up to provide a continous flow of oil to the quick couplers when using an attachment.

Work Lights (Back) Indicator:

illuminate when the loader Back light are turned on. This will serve as a reminer to turn them OFF when the loader is not in use.

Engine Oil Pressure Indicator:

This light will illuminate when the engine loses lubrication pressure. Shut off the engine immediately and determine the cause.

This switch is a toggle switch

Push up to turn the dipped beam lights on. This light are located on the rear of the loader.

2.2 CONTROL LEVER HANDLES

1. Spare

2. Spare 3, 4. Right / Left Direction Indicator (optional)

5. Horn

6. Spare

8. Auxiliary Hydraulic Switch

The left hand control lever is for moving the loader forward and reverse. Pushing the lever forward will cause the loader to move forward, and pulling the lever back towards the operator will cause the loader to move in reverse. This lever also operates hydraulic functions (refer to section 2.8 for instructions).

The right hand control lever controls the lift arms and bucket tilt. Pushing the lever forward will cause the lift arms to raise, while pulling the lever back towards the operator will cause the lift arms to lower. Moving the control lever to the left and right will tilt and untilt the bucket. Refer to section 2.10 for detailed operating instructions of this lever.

Ensure liftarm brace is

properly stowed before

raising or lowering lift

arms

IMPORTANT

2. CONTROLS

LH Control Handle

RH Control Handle

Fig. 2.2A

C3933

18. Back Light Switch:

19. Door Window Wiper Switch: This switch is a toggle

switch. Push up to turn the wiper on.

20. Hi-Flow Hydraulic Switch: This switch is a toggle switch. Push up to turn the Hi-Flow hydraulics on. (Not available on all models)

21. Hour Meter: The hour meter records the number of engine operating hours and has a total of 99999.9 hours.

22. Fuel Gauge: The fuel gauge indicates the quantity of fuel remaining in the fuel tank.

23. Ignition Switch: The ignition switch is a three (3) position switch: 'OFF', 'ON', 'RUN' and 'START'. Turn the Turn the key counter clockwise to engage engine 'PREHEAT'. Turn the key clockwise to the 'START' position, this engages the starter The key will be in the 'RUN' position when released. Turn the key to 'OFF' to shut off the engine and remove the key.

C3015

Fig. 2.2B

2. CONTROLS

2.3 SEATAND SEAT BELT

The seat can be adjusted forward or back for operator comfort (Fig. 2.3A)

For your safety the loader is equipped with a seat belt. Before starting the loader adjust and fasten the seat belt (Fig. 2.3B) around you. The seat and seat belt also have integrated safety lock switches whereby the operator must be seated in the seat with the seat belt securely fastened and seat bar lowered before the loader hydraulics can be operated.

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

Fig. 2.3B

C2698

Fig. 2. 3A

C2699

Release

2. 4 SEAT BAR

For operator protection the loader is equipped with a seat bar.

The loader must be started with the operator seated in the loader and the seat bar in the up position. To raise the seat bar, lift up on the bar (Fig. 2.4A). In the up position, the seat bar activates the parking brake and locks out the functions of the control levers including the auxiliary hydraulics.

When down (Fig. 2.4B), the seat bar releases the park brake and the hydraulic controls of the lift, tilt and auxiliary hydraulic circuits.

Before exiting the loader always check the controls by cycling them to ensure that they are in the neutral position.

2. CONTROLS

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

C5295

C5288

Seat󰼿Bar󰼿Up

Fig. 2. 4A

Seat󰼿Bar󰼿Down

Fig. 2. 4B

2. 5 PARKING BRAKE

The loader is equipped with park brakes, located inside the torque motor. The brakes are activated and de-activated by the seat bar, via charge pressure. When the seat bar is in the up position, the brake is activated (Fig. 2.5A). When the seat bar is in the down position, the brake is off (Fig.

2.5B). The loader has a parking brake indication light to warn that

the brake is engaged. When the seat bar is in the down position, activation of the emergency break can be carried out by pushing on the button, located on the ROPS, in front of the left hand control lever handle.

2. 6 THROTTLE CONTROL

The diesel engine throttle control is located on the left hand side of the loader behind the control lever (Fig. 2.6). Engine start and stop are controlled electrically by the ignition key.

Before shutting off the engine, return the throttle control to idle position and allow the engine to cool at least 2 minutes.

Pushing the lever full forward increases the engine speed to maximum high idle. Pulling the lever back decreases the engine RPM.

The engine should always be operated at full speed and the loader travel speed controlled with the steering control lever (See Section 2.8)

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

2. CONTROLS

Seat Bar Up

(Parking󰼿Brake󰼿on)

C5295 Fig.󰼿2.5A

Seat Bar Down

(Parking󰼿Brake󰼿off)

C3776 Fig.󰼿2.5B

Throttle

Control

C5297

High

Speed

Low

Speed

Fig.󰼿2.6

2. 7 LIFT ARM SUPPORT

For safety while performing regular service or maintenance work the loader is equipped with a liftarm support.

The liftarm support, when engaged, prevents the liftarms from dropping if hydraulic pressure is relieved or the right hand control lever is accidentally cycled.

To operate the liftarm support, remove attachment and park on level ground. Lower the liftarms to the ground and stop the engine. Exit the machine and remove pin that holds the liftarm support in stored positon(Fig. 2.7A). Lower the liftarm support to rest on the lift cylinder(Fig.

2.7B). Re-enter the machine and re-assume proper operating positon with the seat belt fastened and start the engine. Slowly raise the liftarms until the support falls onto the cylinder rod. Slowly lower the liftarms until support restricts movement. Stop the engine.

T o remove the liftarm support, enter the loader and assume proper operating position with the seat belt fastened and start the engine, slowly raise the liftarms until the support is free, have a helper pin the support into its stored positon, lower the liftarms to the ground and shut off the engine before exiting the loader.

2. 8 STEERING CONTROL LEVER

The left control lever controls speed, direction and turning of the loader. Loader speed is controlled by the amount the lever is moved from the centre or neutral position. (Fig.

2.8A) The further away from neutral, the faster the travel speed. For maximum power and slow travel speed move the control lever only a small amount.

T o drive the loader forward in a straight line, move the left control lever forward from the neutral position (Fig.

2.8A).

To drive the loader in reverse in a straight line, move the left control lever back from the neutral position (Fig.

2.8A).

The loader is turned by moving the left control lever to the side. To turn right while in forward or reverse travel, ease the control lever to the right. To stop turning, return the lever to a center position. To turn left while in forward or reverse travel, ease the lever to the left from the neutral position. To stop turning, return the lever to a center position (Fig. 2.8A).

For the loader to turn or "skid-steer" within its own length, move the lever to the left or the right from the neutral position. This causes the wheels on one side to turn forward and the wheels on the other side to reverse turning the loader (Fig. 2.8A).

2. CONTROLS

C5298

Fig. 2.7A

C5416

Fig. 2.8A

Liftarm Support,

Stored Position

Fig. 2. 7B

C 5299

Liftarm Support

Resting On Cylinder

C5415

Ensure liftarm brace is

properly stowed before

raising or lowering lift

arms

IMPORTANT

Forward Reverse

Left󰼿Turn Right󰼿Turn

Forward

Left Turn

Reverse

Right

Turn

2. CONTROLS

C5254

Fig. 2.9B

C5416

Fig. 2.9A

C5255

Fig. 2.9C

2.9 ELECTRIC SOLENOID AUXILIARY CONTROLS

Auxiliary hydraulics (solenoid operated - standard) will only operate with the seat bar down.

A switch located on the R.H. steering control lever (Fig.

2.8A) is used to engage the loader's auxiliary hydraulic

circuit to power attachments such as post hole augers, sweepers, etc. Pressing and holding the switch in position 1 (fig. 2.8A) provides hydraulic flow to the female quick connect coupling located at the front of the lift arms (fig.

2.8C). Releasing the switch returns the auxiliary hydraulic

circuit to neutral, stopping the hydraulic flow.

Pressing and holding the switch in position 2 (fig. 2.8A) provides hydraulic flow to the male quick connect coupling located at the front of the lift arms (fig. 2.8C). releasing the switch returns the auxiliary hydraulic circuit to neutral, stopping hydraulic flow.

For continuous flow to the auxiliary hydraulic circuit, a toggle switch is located on the L.H. instrument panel (fig.

2.8B). Placing the switch in the "ON" position provides

continuous hydraulic flow to the female quick connect coupling located at the front of the lift arms (fig. 2.8C). To stop hydraulic flow to the auxiliary hydraulic circuit, return the switch to the "OFF" position (fig. 2.8B). When the switch on the instrument panel is in the "ON" position, the switch located in the L.H. control lever is not operable.

NOTE: See Section 2.2 for information on the control handles.

AUXILIARY HYDRAULIC CONTROL

NEUTRAL

TOGGLE SWITCH

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the controls to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

Female Quick Coupling

Male Quick Coupling

ROPS󰼿SIDESEAT󰼿SIDE

2. 10 LIFTARM CONTROLS

The right hand control lever (Fig. 2.10) operates the loader•s liftarm and bucket hydraulic system. Refer to section 2.8 for instructions on steering control.

When the control lever is in the neutral position, the lift and tilt functions are static, the work attachment position should not change unless the control lever is moved. If the work attachment does move, service to hydraulic controls is required.

Having the control lever in the neutral position does not affect auxiliary hydraulics. Auxiliary hydraulics are controlled separately and will continue to operate with the control lever in the neutral position.

FLOAT (A)- Pushing the control lever all the way forward will lock the lever in liftarm float detent. This float position allows the work attachment to follow the contour of the ground. Lever will remain locked in float position until it is pulled out of float position.

LOWER (B)- To lower the liftarm, push the control lever straight forward from the neutral position, the control lever will return to the neutral position when released.

NEUTRAL (N)- Neutral (hold) position, lift and tilt functions are static. Liftarms should hold their position.

RAISE(D)- Pulling the control lever back from the neutral position will raise the liftarms, releasing the control lever will allow it to return to the neutral position.

TILT BACK (E)- Moving the control lever to the left will tilt the work attachment back (roll back bucket), releasing the control lever will allow it to return to a neutral position.

TILT FORWARD (F)- Moving the control lever to the right will tilt the work attachment forward (dump bucket), releasing the control lever will allow it to return to a neutral position.

By moving the control lever between two positons, both functions can be done at the same time.

- Move the lever diagonally between lower and tilt forward (B-F) to do both at the same time (lower and roll the work attachment forward).

-Move the lever diagonally between raise and tilt back (DE) to do both at the same time (raise and roll the work attachment back).

-Move the lever diagonally between raise and tilt forward (D-F) to do both at the same time (raise and tilt the work attachment forward).

-Move the lever diagonally between lower and tilt back (B-E) to do both at the same time (lower and tilt the work attachment back).

2. CONTROLS

To prevent personal

injury do not operate the

loader without lowering

the safety bar, fastening

the seat belt and keeping

feet on the cab floor.

WARNING

To avoid personal injury,

lower the lift arms, shut

off the engine, raise the

seat bar and cycle the hydraulics to ensure they are locked. Then unlatch

the seat belt and exit the

loader. Do not enter or

exit with the engine

running unless as

specified in this manual

or under specific service

and backhoe operating

procedures.

WARNING

C5413

Fig. 2.10

C5325

C5414

2.11 QUICK - TACH

The quick-tach, which is standard equipment, allows changing from one attachment to another quickly without having to remove bolt or pins.

To operate, (Fig. 2.11A), lift the locking lever (1) up to completely retract the locking pins (2). Tilt the quick - tach frame forward (Fig. 2.11B) with the bucket tilt cylinders and drive into the attachment. Retract the bucket tilt cylinders (Fig. 2.11C) which will line up the bottom of the attachment with the quick - tach lock pins. Shut off the engine.

Push the locking lever (1) fully down (Fig. 2.11D) extending the lock pins (Fig. 2.11E item 2) through the attachment and securing the attachment.

Before operating the attachment check that the locking pins are correctly engaged.

After hooking up the

attachment check to be

sure pins and locking

levers are correctly

engaged.

WARNING

C5359

C5410

Fig. 2.11B

Fig. 2.11A

C5412

C 5357

Fig. 2.11E

Fig. 2.11D

C5411

Fig. 2.11C

2. CONTROLS

2.12 ELECTRICAL PANEL

The loader is equipped with a 12 volt, negative ground electrical system. The fuse and relay panel is located in the engine compartment on the underside of the engine cover. The panel consists of the following(Fig.2.12):

1. Engine Pre-Heater Relay.

2. Starter Relay.

3. Fuse Panel.

4. Turn Signal Flasher (optional)

5. Head Lamp. (20A)

FUSE PANEL (3)

6. Rear Lamp. (10A)

7. Wiper (15A)(Optional)

9. Front Horn. (10A)

10. Cigar Jack. (15A)

11. Aux, Hyd, Solenoid. (10A)

12. Alternator Light. (10A)

13. Brake Valve Solenoid. (10A)

14. Shut Down. (15A)

2. CONTROLS

Fig 2.12

8. Back up Alram. (10A)

C5256

3. OPERATION

3. 1 Starting Instructions

1. Pre-Starting Inspection

2. Starting Procedure

3. Shut-Off Procedure

3. 2 Operating Procedures

3. 3 Filling From a Pile

3. 4 Digging With a Bucket

3. 5 Leveling and Backfilling

3. 6 Auxiliary Hydraulics

3. 7 Lifting

3. 8 Towing

3. 9 Securing and Transporting

3. 10 Lowering Lift Arms

3. 11 Accumulator

3. OPERATION

3.1 STARTING INSTRUCTIONS

1. Pre-Starting Inspection

Before starting the loader complete the following inspection:

(1) Check the hydraulic oil level, engine oil level, engine

coolant level and fuel supply. (2) Check for fuel, oil and hydraulic leaks. (3) Check lights, battery level and cables. (4) Check tire pressure:

10.00 x 16.5 . . . . 40 - 45 PSI (276 - 310 kPa)

(5) Check wheel nut torque 100 - 110 ft. lbs. (13.8 - 15.2

kgm) (136- 149 Nm). (6) Lubricate all grease fittings. (7) Check the condition and operation of all safety decals

and equipment … Ensure all shields and safety screens

are in place. If necessary repair or replace before

starting. For complete daily servicing refer to section 4. 3.

2. Starting Procedure

1. Ensure the seat bar is in the UPposition and the control

levers are in neutral.

2. Adjust and fasten the seat belt securely around you.

3. Place the throttle control in idle position.

4. Turn the ignition key counter clockwise to activate the

glow plugs. Both the alternator and engine oil pressure

warning lights should be on. Use chart for correct pre-

heat times.

Glow Plug Pre-Heat Times

Ambient Temperature Preheat Time

0 C(32 F) and Above 10 Seconds

-18 C(0 F) to 0 C(32 F) 30 Seconds

-23 C(-10F) to -18C(0 F) 60 Seconds

-29 C(-20 F) to -23 C(-10 F) 120 Seconds

5. Turn the key clockwise to start position to engage the starter. Do not crank the starter for more than 30 seconds. If the engine fails to start turn the key to off position, wait one minute, and repeat the procedure. If engine does not start after three attempts, check the fuel suppply system. The absence of blue or white smoke during cranking indicates that no fuel is being delivered.

6. When the engine has started the engine oil pressure and alternator warning lights should go out. If they

t, shut - off the engine immediately and determine

cause.

7. Allow the engine to warm up for five minutes before operating. When ready to operate, lower the seat bar and advance the throttle to full on position.

This engine is equipped

with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

Overvoltage (14 volts or

greater) will immediately

destroy the glow plugs.

Do not apply overvoltage

to the starting circuit at

any time. If boosting,

use a battery of equal

voltage to the loader and

connect it in

parallel,positive to

positive, negative to

negative.

Limit preheating to

recommended preheat

times; longer periods can

ruin the glow plugs.

IMPORTANT

3. OPERATION

To avoid personal injury

do not start the engine

unless you are in the seat

with the seat belt

fastened around you, unless as specified in this manual or under specific

service and backhoe

operating procedures

WARNING

To prevent personal

injury do not operate the

loader without lowering the safety bar, fastening

the seat belt and keeping

feet on the cab floor.

WARNING

don'

WARNING

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulic

controls to ensure they are

locked. Then, unlatch the seat

belt and exit the loader. Do

not enter or exit with the

engine running unless as specified in this manual or under specific service and

backhoe operating

procedures.

3. Shut-Off Procedure

(1) Select level ground whenever possible. If you must park on

a slope or incline, position the machine at right angles to the slope. Lower the attachment to the ground, engage the

parking brake and bloke the wheels. (2) Lower the lift arms and ground the attachment. (3) Return auxiliary hydraulics to neutral or OFF position. (4) Return the throttle control to idle position. If the engine is

hot allow it to idle until normal, at least 2 minutes. (5) Never enter or exit the loader when the engine is running. (6) Raise the seat bar to apply the park brake. Turn the ignition

switch to the OFF position, remove the key, unfasten the

seat belt, and ensure the hydraulic controls are locked by

rocking them.

3. OPERATION

3. 2 OPERATINGPROCEDURES

1. When learning to use the loader, operate at a slow rate.

2. Take advantage of the efficient operation of the loader.

Keep the travel distance as short as possible. Keep the work

area small so the cycle time is short.

3. Keep the work area as level as possible.

4. Decrease cycle time by "Skid" turning (See Section 2.8A)

rather than a go backward-go forward turn.

5. Fill the bucket to rated capacity . Turning is easier with a full

load than with a partial load. Keep the loaded bucket close

to the ground when transporting.

6. Tilt the bucket as you raise the lift arms or drive up a slope.

This will prevent material from falling off the back of the

bucket.

7. Do not drive across a slope. Always go up or down a slope

with the heavy end of the loader pointing up towards the top

of the slope.

C5363

Handle

Fig. 3.3

3. 3 FILLING FROM A PILE

Fig. 3.3A--Push ahead on the right hand control lever (1) and lower the lift arms completely down. Push to the right on the right hand control lever (2) and place the cutting edge of the bucket on the ground.

Fig. 3.3B--Push ahead on left hand lever to drive the loader forward slowly into the pile. As the bucket begins to fill pull to the left on the right hand lever (3) to raise the front of the bucket and pull back on the right hand lever (4) to raise the lift arms. When the bucket is full back away from the pile.

Fig. 3.3C--To dump the bucket pull back on the right hand control lever (4) to raise the lift arms, push to the right small amounts as the lift arms are raising to stop material from falling off the back of the bucket. When the bucket is at the correct height for dumping, push to the right on the right hand lever (2) to empty the bucket.

Always let the engine

warm completely before

you begin operation each

day.

IMPORTANT

3. OPERATION

Fig. 3.3A

C5303

Fig. 3.3C

C5304

C5305

Fig. 3.3B

3. 4 DIGGING WITH A BUCKET

Fig. 3.4D--Push ahead on the right hand control lever (1) and lower the lift arms completely down. Push to the right on the right hand lever (2) and place the cutting edge of the bucket on the ground. Drive the loader forward at a slow rate and continue to tilt the bucket down until it enters the ground.

Fig. 3.4E--Pull to the left on the right hand lever (3) to raise bucket edge to increase traction and keep an even digging depth.

Fig. 3.4F--Continue to drive forward until the bucket is full. When digging in hard ground, it is easier to raise (3) and lower (2) the bucket cutting edge with the right hand control lever while slowly driving forward. When the bucket is full, pull to the left on the right hand control lever (3) to roll back the bucket.

To avoid personal injury:

When starting or

operating loader in an

enclosed area make sure

there is enough

ventilation. Exhaust

fumes can kill.

WARNING

3. OPERATION

Fig. 3.4D

To prevent personal

injury always carry the

load low.

WARNING

Fig. 3.4E

C5306

C5307

Fig. 3. 4F

To prevent personal

injury, ensure that the

bucket with the proper

rated capacity is being

used for the job you are

doing.

WARNING

C5308

3. 5 LEVELINGAND BACKFILLING

Fig. 3.5G--Spread dirt on uneven ground by pulling back on the right hand control lever (4) to raise the lift arms and push to the right on the right hand control lever (2) to tilt the bucket down as you drive forward.

Fig. 3.5H--To level the ground; raise the lift arms and tilt the bucket down by pushing to the right on the right hand control lever (2). Push ahead firmly on the right hand control lever (1) to lock the lift arms in the float position. The weight of the lift arms and bucket will hold the bucket on the ground. Drive backward to level material.

Fig. 3.5I--T o fill a hole drive the loader slowly with the bucket low, up to the hole. As the bucket passes the edge of the hole, push to right on the right hand control lever (2) to dump the bucket. When necessary raise the lift arms to empty the bucket.

3. OPERATION

Fig. 3.5H

C5309

Fig. 3.5G

To prevent personal

injury always carry the

load low.

WARNING

C5310

C5311

Fig. 3.5I

3. 6 AUXILIARY HYDRAULICS

Fig. 3.6J--To operate an attachment such as a grapple fork the Auxiliary Hydraulic Control Switch (rocker switch) on the Left Hand Control Lever will be used. Push right of neutral on the Auxiliary Hydraulic Control Switch to open the grapple.

Fig. 3.6K--To close the grapple, push left of neutral on the Auxiliary Hydraulic Control Switch. The right hand control lever can be used to raise and tilt the grapple as with a bucket.

Fig. 3.6L--To operate an attachment which requires a constant flow of oil, a toggle switch (AUX HYD) on the L.H. instrument panel should be placed in the "ON" position.

When the auxiliary circuit is not in use, switch AUX HYD to the "OFF" position. Otherwise starting the loader may be difficult or impossible to start and damage to the starter may occur.

Return the auxiliary

control to neutral when

not in use otherwise

starting may be

impossible and damage

to the starter may occur.

IMPORTANT

3. OPERATION

Fig. 3.6J

Fig. 3.6K

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to ensure they are locked. Then, unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this

manual or under specific

service and backhoe

operating procedures.

WARNING

C723

C724

C3022

Fig. 3.6L

C5254

Toggle Switch

3. 7 LIFTING (Optional)

The loader can be equipped with features to use in lifting (for example by crane onto a flatbed trailer or a flat car), for securing, and for extraction (from mud or snow). To facilitate this requires the optional lifting lugs.

To lift using a crane, first follow the shut - off procedure in section 3.1-3.

Once this is done, attach properly rated cables, chains or straps to lift points provided (See Fig. 3.7). To prevent marking the operator guard or chafing of the lifting cable, a lifting frame should be used.

3. 8 TOWING

1. When winching or towing a stuck loader from the rear, always lower the lift arms until the attachment is resting on the ground and then follow the shut - off procedure (See Section 3.1-3).

2. When winching or towing a stuck loader from the front, lower the attachment so that the front attachment points are accessible and have an assistant block the attachment, then follow the shut-off procedure (See Section 3.1-3).

3. Attach a properly rated chain, cable or towing strap to the towing point provided (Fig. 3.8).

4. Deactivate the brake system for towing (refer to section 2.5). To do this ensure that the restraint bar is in the down position. Attempting to tow with the restraint bar in the raised position could result in damage to the braking system.

5. The attachment point on the towing or winching equipment should be kept as low as possible and in as direct a line as possible with the stuck loader. A steep tow line angle or side pull could result in upsetting the stuck loader.

3. OPERATION

C5364

Fig. 3.8

Fig. 3.7

C5360

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

IMPORTANT

Never install tie down

chains across the bucket

cylinders. Damage to the

cylinders may occur.

3. OPERATION

3.9 SECURINGAND TRANSPORTING

There are three tie down points provided for securing the skid steer while transporting. One at the lower front and two at the rear (Fig. 3.9).

Be sure the trailer and/or truck is of adequate size and capacity to safely transport your skid steer.

Measure the clearance height of the machine and trailer or truck, and post it in the cab of the truck.

Before loading the skid steer make sure the ramps and parking surface are free of all oil, grease, ice, etc. and of sufficient strength to support the load.

Know the local rules and regulations, and make sure your truck and trailer is equipped with the correct safety equipment.

When loading a skid steer with an attachment, always load the heavy end first.

Once the skid steer has been loaded, lower the attachment to the floor, stop the engine and engage the park brake.

Install chains at the front and rear tie down locations, and securely attach to the transport vehicle.

C5364

Fig. 3.9

C362

SAFE SHUTDOWN PROCEDURES

Stop machine

- Lower the bucket and other attachments flat on the ground

- Position controls in neutral

- Raise operator seat bar to engage parking brake

- Idle engine for short cool-down period

- Stop engine

- Cycle all controls to ensure they are de-activated.

- Raise operator seat bar.

- Check that lift arm/bucket controls are locked in neutral.

- Unbuckle seat belt

- Remove ignition key and lock covers and closures.

C361

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

IMPORTANT

When moving your skid steer

on or off a transport vehicle,

drive slowly and keep the

machine centered.

WARNING

Ramps must be of sufficient

strength to support the

weight of your skid steer.

Wooden ramps can break

and cause personal injury.

3.10 LOWERING LIFT ARMS (ENGINE OFF)

This section is currently under review. You will be notified and supplied with an updated section when it is available.

To avoid personal injury:

Do not leave lift arms up

unless the lift arm support

is engaged.

WARNING

3. OPERATION

C5394

WARNING

To avoid personal injury, always ensure that

the liftarm support is in position before

servicing machine

3. OPERATION

3.11 BATTERY MAINTENANCE AND BOOSTING

Inspect the battery on a regular basis for damage such as a cracked or broken case or cover which would allow electrolyte loss. (Fig. 3.11A)

Check the battery cables for tightness and ensure they are corrosion free. Remove any acid corrosion from battery and cables with a baking soda and water solution. Coat the terminal connections with di-electric grease.

Use caution if it is necessary to use a booster battery to start the engine.

The ignition must be in the off position. The booster battery must be 12 Volt.

C1234

Fig. 3.11A

12V

3. OPERATION

3.12 ACCUMULATOR

The accumulator (fig. 3.11A) stores system pressure until it is required. The key must be placed in the "On" position to operate the electric auxiliary (engine not running).

The electric auxiliary and stored system pressure can be used to activate the spools. This decreases the hydraulic pressure from the male/female couplers located on the lift arms. This is accomplished by cycling the momentary switch on the R.H. control a couple of times (fig. 3.11B).

Once this pressure is decreased the operator can remove/replace the quick attach accessories easily.

C5268

Fig. 3.11A

Accumulator

C3915

Fig. 3.11B

Momentary

Switch, Auxiliary Hydraulic

Rops󰼿SideSeat󰼿Side

4. 1

Preventative Maintenance Service Schedule

4. 2 Service Access

1. Lift Arm Support

2. Tilt Cab

3. Battery Access

4. 3 Daily Service Check

1. Hydraulic Oil Level

2. Air Cleaner

3. Tires and Wheel Nuts

4. Safety Equipment

5. Decals

6. Lubrication

7. Engine Oil Level

8. Radiator / Oil Cooler Service

4. 4 50 Hour Service Check

1. Engine

2. Hydraulic / Hydrostatic

3. Final Drive

4. Controls and Safety Equipment

5. Electrical

6. Grease / Lubrication

7. General

4. 5 250 Hour Service Check

4. 6 Final Drive Maintenance

1. Oil Level Check

2. Adding Oil

3. Drive Chain, Axle and Sprocket Inspection

4. 7 Hydraulic / Hydrostatic System Maintenance

1. Oil Level Check

2. Adding Oil

3. Hydraulic Filter Replacement

4. Draining System Fluid

5. Oil Cooler and Cooling Fan

6. Brake Service Override

4. 8 Engine Maintenance

1. Engine Specification

2. Oil Level Check

3. Engine Oil and Filter Replacement

4. V-Belt Tension

5. Adding Fuel

6. Fuel Filter Replacement

7. Bleeding the Fuel System

4. 9 Air Cleaner Maintenance

1. Daily Maintenance

2. Servicing Cleaner Element

4. 10 Engine Cooling System

4. 11 Electrical System

1. Battery Maintenance and Boosting

2. Electrical Schematic - ROPS

3. Electrical Schematic - Engine

4. 12 Tire Maintenance

1. Tire Inflation and Service

2. Tire Rotation

4. 13 Troubleshooting

1. Hydraulic System

2. Hydrostatic Drive

3. Final Drive Transmission

4. Control Levers

5. Electrical

6. Engine

4. 14 Hydraulic / Hydrostatic Cicuit

4.15 Special Tools

4. MAINTENANCE

Engine Fuel Filter Final Drive Hydraulic reservoir

Engine Cooling System

Replace engine fuel filter. (See Section 4.8-6). Change final drive lubricating oil.

Remove and replace the 100 micron suction element in the oil reservoir. Change hydraulic oil.

Drain, flush and refill. Use 50% mixture of ethylene glycol and water.

ITEM SERVICE REQUIRED

Engine Oil

Hydraulic Oil

Radiator

Air Cleaner

Tires and Wheel Nuts

Safety Equipment

Decals

Lubrication Hydraulic Oil Filter 50 Hour Service Engine Oil Engine Oil Filter Final Drive Hydraulic Oil Filter(s)

Preventative Maintenance Service Check

Engine Oil

Engine Oil Filter

Check level and add if necessary. Use 10W30 API Classification SJ.

Check level and add if necessary. Use10W30 API Classification SJ.

Check level and add if necessary. Fill with 50% mixture of ethylene glycol and water. Check cooling fins for dirt. If necessary blow out with compressed air.

Empty dust cap. Check condition indicator and service or replace element as required.

Check for low pressure or tire damage, refer to Section 5.1 for more information. Check wheel nut torque 100-110 ft. lbs. (136-149 Nm).

Check all safety equipment for proper operation and condition. Seat belt, lift arm supports, quick-tach locks, parking brake, hydraulic control locks, safety treads, front shield and cab side screens. If necessary repair or replace.

Check for damaged safety or instruction decals (See Section 5.3). If necessary replace.

Grease all hinge pin fittings and pivot bearings until excess shows. Replace hydraulic oil filter element. Initial change only. Perform complete 50 hour service (See Section 4.4).

Replace engine oil. Use 10W30 API Classification SJ.. (See Section 4.8-3). Replace engine oil filter.

Check chain and sprocket condition. Check every 200 hours. Replace hydraulic oil filter element (See 4.7-3).

It is recommended as a preventative maintenance procedure that the 50 hour service be repeated every 200 hours. (See Section 4.5)

Replace engine oil. Use 10W30 API Classification SJ. See 4.8-3. Replace every 200 hours.

Replace engine oil filter. See 4.8-3. Replace every 200 hours.

4.1 PREVENTIVE MAINTENANCE SERVICE SCHEDULE

4. MAINTENANCE

50 HOURS

8 HOURS

1000 HOURS

200 HOURS

WARNING

To avoid personal injury

service repairs must be

performed by an

authorized SUNBEAR

dealer.

4. MAINTENANCE

WARNING

WARNING: Escaping hydraulic

fluid under pressure can

penetrate the skin causing

serious injury.

€ DO NOTuse your hand to check

for leaks. Use a piece of cardboard

or paper to search for leaks.

€ Stop engine and relieve pressure

before connecting or disconnecting

lines.

€ Tighten all connections before

starting engine or pressurizing

lines.

If any fluid is injected into the skin

obtain medical attention

immediately or gangrene may

result.

4. 2 SERVICE ACCESS

1. Lift Arm Support

For safety while performing regular service or maintenance work, the loader is equipped with lift arm support. When properly used, the lift arm support prevents the lift arms from dropping if hydraulic pressure is relieved or the hydraulic controls are accidentally cycled during routine maintenance.

To operate the lift arm support, remove attachment, park on level ground. Lower liftarms to ground and stop engine. Exit the machine and remove pin that holds liftarm support in stored positon(Fig. 4.2A). Lower liftarm support to rest on lift cylinder(Fig. 4.2B). Re-enter the machine, assume proper operating positon with seat belt fastened and start engine. Slowly raise liftarms until support falls onto the cylinder rod. Slowly lower until support restricts movement. Stop engine. (Fig. 4.2C)

To remove support, sit in loader, fasten seatbelt, start engine and lower seat bar. Raise liftarms enough to release support. have a helper raise support and pin it into position, lower liftarms and stop engine.

Liftarm Support,

Stored Position

C5298

Liftarm Support

Resting On Cylinder

Fig. 4.2A

C 5299

Fig. 4. 2B

2. Tilt Cab

The cab assembly can be tilted up at the front to provide access to the controls, hydraulic and hydrostatic components. To tilt the cab assembly, remove the bolts located at the front corners of the cab,close and latch cab door if so equipped, tilt cab up and insert prop rod (Fig.4.2D and 4.2E). To close, remove prop rod from cab and store in clip on top of transmission, pull front of cab down until cab rests on front of loader. Re-install front cab bolts and torque to 78-84 lb/ft..

3. Battery Access

The battery is located in a compartment found under the operators seat. Remove the bolts that hold the front corners of the cab, tilt cab up and insert cab prop rod. Battery is located in a tray above the left side transmission.

Ensure lift support is

properly stored before

resuming normal loader

operation.

IMPORTANT

To avoid personal injury:

Do not leave lift arms up

unless the lift arm

support is engaged.

WARNING

4. MAINTENANCE

Fig. 4.2D

C5270

C5266

Fig. 4.2E

Fig. 4.2C

C5396

Lift Arm Fully Raised

Cab󰼿Rrop󰼿Rod

Battery

Cancellation󰼿shook off󰼿after󰼿pressing, to󰼿get󰼿off󰼿the󰼿cap.󰼿

4. 3 DAILY SERVICE CHECK

1. Hydraulic Oil Level

Check the oil level with the machine on a level surface with the lift arms down and the attachment grounded. Open the rear door and check the oil level sight tube (Fig.

4.3A). If oil is apparent the oil level is satisfactory. If necessary to add oil, remove the reservoir cap located

at the top of the oil reservoir and add oil until oil appears in the oil level sight tube.

2. Air Cleaner

The loader is equipped with an air cleaner restriction warning lamp. Should this lamp illuminate, shut off the engine and determine cause. Possibly a plugged air filter

Check that all hose clamps are tight and the hose is undamaged. Check the vacuator valve for damage (Fig

4.3B). See Section 4.9 for Air Cleaner Maintenance.

4. MAINTENANCE

C5262

WARNING

To avoid personal injury:

Stop, Cool and Clean the

engine of flammable

materials before

servicing. Never service

or adjust machine with

engine running.

Fig. 4.3A

Sight Tube

󰼿

C5319

Vacuator Valve

Fig. 4.2F

Air Cleaner

C5267

Fig. 4.3B

3. Tires and Wheel Nuts

Inspect tires for wear or damage. Check and inflate tires to correct pressure:

10.00 x 16.5 ...........40 - 45 PSI (276 - 310 kPa)

To prevent shearing of the wheel studs and rim damage check wheel nuts for proper torque 100 -110 lbs. ft. (136 149 Nm) daily (Fig. 4.3C). After changing a rim, Check wheel nuts hourly, until the reading stabilizes.

4. Safety Equipment

Check all safety equipment for proper operation and condition - seat belt, lift arm support, seat bar, steering neutral lock, parking brake, quick tach lock, shields and safety treads. Lubricate all linkages, springs and pivot points with a silicone based lubricant. Repair or replace if necessary.

5. Decals

Check the condition of all safety and instruction decals. Replace any damaged or missing decals. Refer to Section

5.3 for decal description and locations.

6. Lubrication

There are fourteen (14) grease fittings located in the loader that require lubrication every eight hours. Lubricate with a good quality multi-purpose lithium based grease. Apply grease until excess shows. Refer to the service schedule for complete service details. (See Fig. 4.3D). The fourteen (14) lubrication points are:

Rear Lift Arm Pivots (2) Lift Cylinder Bushings (4) Bucket Cylinder Bushings (4) Quick Tach Pivot and Lock Pins (4)

7. Engine Oil Level

Check the oil before engine start up. If the engine has been running let it cool for at least 5 minutes to allow the oil to drain back to the oil pan.

To check the oil level, check with the loader on level ground, open the rear door and remove the dipstick (Fig.

4.3E). Keep the oil level between the full and low mark on the

dipstick (Fig. 4.3F). Do not fill above the full mark. Use API Classification Ch-4 oil.

4. MAINTENANCE

C5251

Fig. 4.3D

Torque Wheel Nuts 100 - 110 lbs. ft. (136 - 149 Nm)

Fig. 4.3C

Fig. 4.3E

C5353

Fig. 4.3F

OVERFULL

LOW , ADD OIL

Dipstick

Location

C5267

8. Radiator / Oil Cooler Service

With the engine cool, check the coolant level in the overflow reservoir (fig. 4.3G). Ensure the coolant level is at the Full-Cold mark on the reservoir by adding 50% mixture of ethylene glycol and water if required.

The radiator and oil cooler fins must be kept free of debris otherwise overheating of the engine will occur. Inspect the radiator cooling fins for damage or buildup of debris. Repair any damage and if necessary flush the radiator with compressed air to remove debris.

4. 4 50 HOUR SERVICE CHECK

The following service check is to be performed by your dealer after the first 50 hours of operation.

1 Engine

1.1 Oil and Filter: Change the engine oil and filter. Use only original

replacement parts. Change the oil every 200 hours thereafter. Change the filter every 200 hours thereafter.

1.2 Radiator: Check the coolant level. If necessary flush the radiator

with compressed air. A dirt buildup on the radiator cooling fins can cause both engine and hydraulic system overheating.

1.3 Fan Drive: Inspect fan, bolts, v-belt and guard to ensure there is

no buildup of dirt, trash, or wear. Use compressed air to clean the area.

1.4 Fuel System for Leaks: Make a visual inspection of fuel system for leaks and

potential hazards such as fuel line(s) touching exhaust manifold, flywheel, etc. Replace fuel filter every 300 hours.

1.5 Air Intake and Cleaner System: Visually inspect the air cleaner system and be sure all

hose clamps are secure and no hoses are damaged.

1.6 Exhaust System: Visually inspect the exhaust system and ensure all

clamps are secure and the manifold bolts/nuts are tight.

1.7 Engine Speed: Check, and if necessary adjust engine RPM.

4. MAINTENANCE

Keep the rear door

closed except for

servicing. Make sure the

door is closed and

latched before operating

the loader.

IMPORTANT

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

Coolant Overflow

Reservoir

C1663

Fig. 4.3G

2 Hydraulic/Hydrostatic

2.1 Hydraulic Oil Filter: Change the hydraulic filter now and every 200 hours

after the initial change. Lubricate the filter cartridge seal with system fluid.

2. 2 Hydraulic Oil Level: If oil is visible in the oil level sight glass the level

satisfactory. If not add oil.

2.3 Hoses and Pipes: Make a visual inspection of all hydraulic lines and

fittings for leaks. Check that steel lines do not touch one another.

2.4 Cylinders: Inspect cylinders for leaks. Extend cylinders and

check for rod damage.

2.5 Hydraulic Functions: Check that the following operate properly: control

valve float position, auxiliary hydraulic and hydraulic cylinders.

2.6 Pumps, Motors, and Controls Leakage: Inspect pumps and motors for leaks.

2.7 Oil Cooler: Inspect the oil cooler for leaks, fin damage or clogged

with dirt. If necessary flush fins with compressed air.

3 Final Drive

3.1 Oil Level: Check lubricating oil level. If necessary add oil.

3.2 Drive Chain Condition: Check drive chains for any sign of wear or damage.

Check lubrication oil in housing for signs of contamination.

3.3 Hydrostatic Motor Mounting Bolts: Check torque 85 - 90 ft. lbs. (115 - 122 Nm)

3.4 Bearing End Play: Check axle bearings for loss of bearing pre-load. If

necessary, adjust the bearings for zero end play.

3.5 Axle Seal: Inspect axle seal area. Clean area of debris build up

and visually check for seal damage, replace as required.

4 Controls and Safety Equipment

Seat Bar Switch Check: Raise the seat bar and check that the

hydraulic controls are not functional.

Seat Belt Switch Check: Unbuckle the seat belt and check

that the hydraulic controls are not functional.

Seat Switch Check: With the seat bar down and the seat belt

connected loosely around you, raise your weight off the seat and check that the hydraulic controls are not functional.

4.1 Engine Throttle Control: Check that the throttle control operates freely without

binding or slackening off due to vibration.

4. 2 Parking Brake: Check that the parking brake engages and completely

disengages. The park brake automatically engages with seat bar up.

4. 3 Lift Arm Supports: Check that the lift arm support will operate without

binding.

4.4 Quick-Tach, Operation & Linkage: Ensure the quick-tach linkage operates smoothly

without binding and engage completely.

4.5 Seat Belt: Check seat belt condition. If necessary replace.

4. MAINTENANCE

To avoid personal injury:

never repair or tighten

hydraulic hoses or

fittings with the engine

running or the system

under pressure.

WARNING

5 Electrical

5.1 Battery (s): Maintenance Free.

5.2 Battery Terminals: Check battery terminals for corrosion. If necessary,

clean.

5.3 Starter Operation: Engage and disengage the starter a few times to ensure

it•s working properly. To prevent starter damage do not engage for more than 15 seconds. Allow 1 minute between starting attempts for cooling the starter.

5.4 Operation of Electrical Equipment: Make a complete check of all electrical equipment,

gauges, warning devices, pre- heater indicator, work lights, seat and seat belt switch, seat bar switch and all optional equipment to ensure they are operating correctly.

6 Grease/Lubrication

Lubricate the following points with a good quality grease every 8 hours. Numbers marked ( ) indicate the number of fittings at each location.

Rear Lift Arm Pivots (2) Lift Arm Cylinder Bushings (4) Bucket Cylinder Bushings (4) Quick - Tach Pivot (4)

7 General

7. 1 Tire Pressure: Check tire pressure and if necessary inflate to the

following pressures:

10.00 x 16.5 . . . . . . . 40 - 45 PSI (207 - 241 kPa)

7. 2 Wheel Nut Torque: Check and torque wheel nuts to 100 - 110 ft. lbs. (136

- 149 Nm).

7.3 Condition of Cab: Inspect both the seat and seat belt. Ensure all safety and

instruction decals are in place. Inspect sound insulation, side windows and door operation for machines equipped with cab enclosure kits. Inspect for structural damage and alterations to R.O.P.S.

7. 4 Condition of Shields and Safety Equipment: Inspect and ensure all shields are in place and

securely fastened. Inspect and ensure all safety equipment is working properly. Ensure owners and operators manual,

safety manual and all safety and

instruction decals are in place. If necessary, replace.

7. 5 General Condition: Make a general inspection of the machine looking for

loose or missing parts, oil leaks, etc.

4. 5 200 HOUR SERVICE CHECK

Initial 200 hour check should be performed by an authorized dealer.

1. It is recommended that the 50 hour check (see Section 4.4) be repeated at 200 hours.

4. MAINTENANCE

4. 6 FINAL DRIVE MAINTENANCE

1. Oil Level Check

The loader has two independent final drive housings. Check the lubricating oil level with the loader on a level surface. Remove the check plug (Fig. 4.6A) located on the front of the loader to determine the oil level. The oil level should be checked after 50 operating hours and every 200 hours thereafter. It is recommended the oil be changed after 1000 operating hours or if it shows signs of contamination.

2. Adding Oil

Add oil with the loader on level ground. Remove the oil level check plug (Fig. 4.6A) on the final drive housing. Raise cab (Section 4.2) and remove the front foot shields. Remove the filler cap (Fig. 4.6B & Fig. 4.6C). Fill to the level of the check plug. (Fig. 4.6A)

3. Drive Chain, Axle and Sprocket Inspection The condition of the drive chains should be checked after

the first 50 hours of operation and every 200 hours thereafter.

To inspect, block the loader securely with all four wheels off the ground. Remove both the front and rear wheels. On reassembly torque the wheel nuts to 100-110 ft. lbs. (136149 N m). Remove the inspection cover on the side of the chain drive housing.

Inspect the chain for any sign of wear, damage or excessive looseness. Inspect the sprockets for any sign of damage or excessive wear. Inspect the lubricating oil for signs of contamination. Check the axle bearings for loss of bearing preload. If necessary adjust the bearings for zero end play.

Check the axle seals for leaking oil or damage. Replace seals at first sign of problem.

4. MAINTENANCE

Fig. 4.6A

C5276

Filler Cap

Fig. 4.6B

C5268

C5269

Fig. 4.6C

Filler Cap

Check Plugs

4. 7 HYDRAULIC/ HYDROSTATIC SYSTEM MAINTENANCE

1. Oil Level Check

Check the oil level of the hydraulic reservoir with the machine on a level surface with the lift arms down and the attachment grounded. Shut off the engine. Open the rear door and check the oil level sight glass (Fig. 4.7A). If oil is apparent the level is satisfactory.

WARNING

WARNING: Escaping hydraulic

fluid under pressure can

penetrate the skin causing

serious injury.

.DO NOT use your hand to check

for leaks. Use a piece of cardboard

or paper to search for leaks.

. S top engine and relieve pressure

before connecting or disconnecting

lines.

. Tighten all connections before

starting engine or pressurizing

lines.

If any fluid is injected into the skin

obtain medical attention

immediately of gangrene may

result.

4. MAINTENANCE

C5262

Oil Level Sight tube

Fig. 4.7A

2. Adding Oil To add oil, remove the oil filler cap located at the top of the

oil reservoir (Fig. 4.7B). Check and ensure the filter screen in the filler neck is undamaged. Add ISO VG32 oil until oil is visible in the oil level sight glass (Fig. 4.7A).

3. Hydraulic Filter Replacement

The hydraulic oil filter (Fig. 4.7C) must be changed after the first 50 hours of operation and every 200 hours thereafter.

To change the filter; shut off the engine, lower the lift arms, ground any attachment and set the parking brake. Open the rear door and using an oil filter wrench remove the filter element. Lubricate the new filter seal with system fluid and reinstall hand tight.

4. Draining System Fluid

Change the hydraulic oil:

1. After 1000 operating hours.

2. If the oil has become contaminated.

3. After any major hydrostatic repair.

To drain the oil: remove the drain plug located at the bottom of the reservoir (Fig. 4.7D). Have a container(s) ready to hold approximately 20 gallons (76 liters) of fluid. Remove any metal particles stuck to the magnet. Seal the plug with teflon tape when replacing.

4. MAINTENANCE

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to ensure they are locked. Then, unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

Fig. 4.7B

Fig. 4.7D

C5263

C5252

SUNBEAR recommends

that you abide by all

applicable enviromental

regulations when

disposing of oil.

IMPORTANT

OIL FILLER CAP

C5252

Fig. 4.7C

Hydraulic Filter

OIL RESERVOIR

DRAIN

5. Oil Cooler and Cooling Fan

Oil returning from the control valve is circulated through the oil cooler before being sent to other parts of the hydraulic system.

An engine cooling fan drives air through the oil cooler. Refer to Figure 4.7E.

The oil cooler should be checked daily for dirt buildup on the cooling fins. If the air flow is restricted through the cooling fins, overheating of the hydraulic system may occur. Clean any dirt buildup with compressed air. Flush with water if necessary. Figure 4.7E shows the radiator/oil cooler setup for the loader.

6. Brake Service Override

A service override has been incorporated for use by SUNBEAR Dealers.

The normal position of the plunger

is down and turned into the locked position (Fig. 4.7F). To release the park brake, turn the release button counter

-clockwise (Fig.4.7F). Go to the rear of the machine and pressurize the small quick coupler to 200 psi to release the park brake (Fig. 4.7G).

4. MAINTENANCE

Fig. 4.7E

C5319

Fan

To avoid eye injury

always use safety goggles

when cleaning with

compressed air.

WARNING

Fig. 4.7F

C5260

C5259

Fig. 4.7G

Brake Quick

Coupler

Brake Release Valve

Oil Cooler

Plungers

2. Oil Level Check

Check the oil before engine start up. If the engine has been running let it cool for at least 5 minutes.

To check the oil level, stop the engine with the loader on level ground, open the rear door and remove the dipstick (Fig. 4.8A).

Keep the oil level between the full and low mark on the dipstick. Do not fill above the full mark.

3. Engine Oil and Filter Replacement

Operate the engine until warm, approximately 5 minutes. Stop the engine. Remove the oil drain plug located at the bottom of the oil pan. Remove the oil filter (Fig. 4.8B). Clean the filter housing surface. Put clean oil on the seal of the new filter and install the filter hand tight.

Replace the oil drain plug. Remove the filler cap and add engine oil. Start the engine and run for 5 minutes. Stop the engine and check for leaks at the filter. Recheck the oil level and add oil until the level is at the top mark on the dipstick. Check daily and change every 200 hours.

WARNING

To avoid personal injury:

Stop, Cool and Clean the

engine of flammable

materials before

servicing. Never service

or adjust machine with

engine running.

4. MAINTENANCE

C5267

Fig. 4.8A

C5323

Fig. 4.8B

Engine Oil

Filter

SUNBEAR recommends

that you abide by all

applicable enviromental

regulations when

disposing of oil.

IMPORTANT

4. 8 ENGINE MAINTENANCE

1. Engine Specification

Make............................................................................................Cummins

Model...........................................................................................A2300T

No. of Cyls ..................................................................................4

Horsepower (Gross) ................................................................ 60

Power (ISO9249 Net Power) ......................................................44.7kW

High Idle............................................................................. ........2800

Max. Torque ................................................................................135(18.7kg/m@ 1600)

Displacement...................................................................... ........139cid(2290cc)

Engine Oil ...................................................................................7.5 US qts.(7 L)

Firing Order.................................................................................1-3-4-2

Alternator.....................................................................................45A

Oil Check.....................................................................................Daily

Oil Change..........................................................................First@50 hrs.........Second@200 hrs.

Filter Change......................................................................First@50 hrs.........Second@200 hrs

Dipstick

Location

4. V-Belt Tension

Check the V-belt tension midway between the crankshaft pulley and alternator pulley (Fig. 4.8C). Deflection should be between 1/4 to 3/8 in. (7-9 mm).

5. Adding Fuel

Use No. 2 diesel fuel only. Total tank capacity 20 gal. (76L). Before adding fuel to the loader the key switch must be off and the engine must be cool. Remove the fuel cap (Fig. 4.8D). Use a clean approved safety container to add fuel. Add fuel only in an area that is well ventilated and away from open flames or sparks - NO SMOKING!

6. Fuel Filter /Water Separator

The fuel filter/water separator is located in the engine compartment on the right hand side (Fig. 4.8F). The fuel filter/water separator should be drained of water daily.

SHUT OFF ENGINE

Drain the water-fuel separator into a container and dispose of in accordance with local enviormental regulations. To drain, turn the drain valve (Fig.4.8G) on bottom of filter counterclockwise approximately 3-1/2 turns until the valve drops down 1" and draining occurs. Drain the filter sump until clear fuel is visible. To close the valve, lift the valve and turn clockwise until it is hand tight.

To replace the filter close the fuel inlet line shut - of f located on the side of the fuel tank (Fig. 4.8E). Remove the filter element (Fig. 4.8F). Lubricate the seal on the new filter and install the filter hand tight. Open the fuel inlet shut - off. It may be necessary to remove air from the fuel system after changing the filter element. (Refer to Section

4.8-7).

Fig 4.8E

Fuel Inlet Shut - off

Fig. 4.8F

C5265

4. MAINTENANCE

Alternator

Pulley

Fan Pulley

Crankshaft Pulley

Fig. 4.8C

C-5321

Fuel Cap

C5258

Fig.4.8D

To avoid personal injury

never add fuel to the

loader when the engine is

running or is hot. NO

SMOKING.

Fuel Filter

C5423

Fig. 4.8G

Drain Valve

C5257

WARNING

7. Bleeding the Fuel System

Air must be removed from the fuel lines, after replacement of the fuel filter element, or when the tank has been run out of fuel, before starting the engine.

T o remove air , ensure the fuel inlet shut-of f located on the side of the fuel tank is open (Pg. 43, Fig. 4.8E). Open the air bleed screw on fuel filter head by turning it counter clockwise (Fig.

4.8H) . Operate the priming pump plunger until the fuel flowing from the bleed screw is free of air. Close the air bleed screw on the fuel filter head.

Bleed Low Pressure Fuel Lines

Note: Use this procedure only if the air bleed screw fails

to remove air from the system.

Open fuel return line bleed screw on the pump (Fig. 4.8I). Hold the banjo bolt with a wrench while using a second wrench to open bleed screw.

Operate the plunger on the fuel filter head until the fuel flowing from the bleed screw is free of air.

Tighten the fuel return line bleed screw on the fuel pump using one wrench to hold banjo bolt while tightening the bleed screw with a second wrench.

Air Bleed Screw

Plunger

Push Down

C5354 Fig. 4.8H

Drain Valve

Bleed Screw

C5424

C5366

Fig.4.8J

Fuel Droplets

Fig. 4.8I

4. MAINTENANCE

4. 9 AIR CLEANER MAINTENANCE

1. Daily Maintenance

Inspect the air cleaner canister for holes, dents, missing or mis-aligned gaskets. Check all hose clamps for tightness and inspect the hose and vacuator valve for damage (Fig. 4.9A).

2. Servicing Cleaner Element (Fig. 4.9B) DO NOT open unless the indicator indicates a blocked

filter or under normal scheduled servicing. To check the indicator, with the engine running, block half of the intake inlet and check the indicator on the dash panel. It should illuminate to simulate a blocked filter.

2.1 Unlatch and remove the cover assembly

2.2 Release The Seal Gently - The filter should be removed gently to reduce the amount of dust dislodged. Move the end of the filter up and down and side to side or twist to break the seal.

2.3 Avoid Dislodging Dust From The Filter - Gently pull the filter off the outlet tube. Avoid knocking the filter against the housing.

2.4 Always Clean The Sealing Surface Of The Outlet Tube - Dust on the outside diameter of the housing could hinder an effective seal.

2.5 Always Clean The Inside Of The Outlet Tube - Dirt inside of the outlet tube will reach the engine : it only takes 9 grams of dirt to dust an engine.

2.6 Check Your Old Filter - Inspecting your old filter will detect foreign material on the sealing surface that may causing leakage.

2.7 Inspect the new filter for seal or pleat damage.

2.8 Insert the new filter properly - The seal area is on the inside of the open end of the primary filter. A new filter has a dry lubricant to aid installation. The critical sealing area will stretch slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure at the outer rim of the filter, not the flexible centre. No cover pressure is required to hold the seal.

2.9 Check connections and ducts for air tight fit - Make sure all clamps, bolts and connections are tight. Check for holes in piping. Leaks here send dust directly to the engine.

2.10 DO NOT reuse filters.

4. MAINTENANCE

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this

manual or under specific

service and backhoe

operating procedures.

WARNING

To avoid personal

injury: DO NOT charge

a frozen battery because it can explode and cause

personal injury. Let the

battery warm to 60°F.(15.5°C.) before putting on a charger.

WARNING

Inlet

Outlet

Cover Assembly

Vacuator Valve

Latch

Safety Filter

Primary

Filter

C-653

Fig. 4.9B

Fig 4.9A

C5277

Air Cleaner

Hose

Vacuator Valve

4. 10 ENGINE COOLING SYSTEM

The engine cooling system fluid is a 50-50 mixture of ethylene glycol anti-freeze and water for both coldweather protection and boil over protection.

To drain the cooling system; locate the rad drain valve on the front right side of the radiator (Fig. 4.10B & 4.10C). Use the attached hose to direct coolant into an appropriate container and open valve to drain radiator.

To completely drain the engine, undo clamp and remove cap from the engine drain nipple located on the engine oil cooler (Fig. 4.10A) and attach a hose to drain coolant into a container. Remove the radiator cap.

To fill the cooling system; re-cap and clamp the drain nipple on the engine oil cooler (Fig. 4.10A) and close the radiator drain valve (Fig. 4.10B & 4.10C). Fill the radiator with a 50-50 mixture of ethylene glycol anti-freeze and water. Refit the radiator cap. (Fig. 4.10D)

C5370

Fig. 4.10A

WARNING

To avoid personal injury:

DO NOT remove the

radiator cap when the

engine is hot.

4. MAINTENANCE

Engine Coolant

Drain

Engine

OilCooler

C5378

Fig. 4.10B

WARNING

To avoid personal injury

never add coolant when the engine is running or

is hot.

C5358

Percentage Ethylene Glycol

Freeze Temp.

Boil Temp.

Rad Cap

C5419

Fig. 4.10C

50 41 32 23 14

-4

-13

-22

-31

-40

-49

-58

-67

-76

-85

-94

-103 0 10 20 30 40 50 60 70 80 90 100

Freezing Point

Boiling Point

329 320 311 302 293 284 275 266 257 248 239 230 221 212 203 194 185 176

Drain Valve

4. 11 ELECTRICAL SYSTEM

1. Battery Maintenance and Boosting

Inspect the batteries on a regular basis for damage such as a cracked or broken case or cover which would allow electrolyte loss.

Check the battery cables for tightness and corrosion. Remove any acid corrosion from the battery and cables with a baking soda and water solution. Coat the terminal connections with di-electric grease.

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operators seat and one person to connect and disconnect the battery cables.

4. MAINTENANCE

WARNING

To prevent personal injury

DO NOT charge a frozen

battery because it can

explode and cause

personal injury. Let the

battery warm to 60

(15.5°C.) before putting on

a charger.

Lead-acid batteries contain

sulfuric acid which will

damage the eyes or skin on

contact. Always wear goggles

to avoid acid in the eyes. If

acid contacts the eyes, wash

immediately with LARGE

QUANTITIES of clean water

and get medical attention.

Wear rubber gloves and

protective clothing to keep

acid off the skin. If acid

contacts the skin, wash off

immediately with clean water.

WARNING

2. ELECTRICAL SCHEMATIC, 1 OF 3

4. MAINTENANCE

2. ELECTRICAL SCHEMATIC, 2 OF 3

4. MAINTENANCE

2. ELECTRICAL SCHEMATIC, 3 OF 3

A M M CS R R L T L L L A/C

3 4 19 18 24 10 25 27 26 17

(A) (B)

S S S S S S

1. Starter

4. Glow plug

7. Engine Oil Pressure Indicator

10. Fuel Level Sender

13. Control Valve Solenoid (A)

16. Backup Alarm

19. Starter Relay

22. Iginition S/W

25. Work Light (Rear)

28. S/W for the Wiper Motor

31. Restraint Bar S/W

L L L L L

HORN

13 14 15 16 12 11 6 7 8 9

▣ INDEX (ELECTRICAL SCHEMATIC) ▣

2. Alternator

5. Engine Shut-off Solenoid

8. Coolant Temp. Sender

11. Brake Valve Solenoid (Left)

14. Control Valve Solenoid (B)

17. Cigar Jack

20. Circuit Breaker (40A)

23. Fuel Gauge

26. Work Light (Front, High)

29. Toggle S/W for the Work Lights

32. Seat S/W

3. Battery

6. Air Filter Service Indicator

9. Hyd. Oil Temp. Sender

12. Brake Valve Solenoid (Right)

15. Horn 18 Pre-heater Relay

21. Fuse Box

24. Hour Meter

27. Work Light (Front, Low)

30. Push Button S/W for the Aux.

33. Seat Belt S/W

4. 12 TIRE MAINTENANCE

1. Tire Inflation and Service

1.1 Upon receiving your loader, check the air pressure in the tires as indicated in the tables.

1.2 Check tire pressure every 8 hours.

1.3 Tire inflation pressure affects the amount of weight which a tire may carry. Do not over-orunder inflate the tires.

1.4 Do not re-inflate a tire that has been run flat or seriously under-inflated until the tire has been inspected for damage by a qualified person.

1.5 When checking tire pressure, inspect the tire for damaged side walls and tread cuts. Neglected damage will lead to early tire failure.

1.6 Be sure the rim is clean and free of rust.

1.7 Lubricate both tire beads and rim flanges with soap solution. Do not use oil or grease.

1.8 Use a clip-on tire chuck with a remote hose and gauge which allows the operator to stand clear of the tire while inflating it.

1.9 After seating the beads, adjust inflation pressure to recommended operating pressure.

1.10 Do not inflate a tire unless the rim is mounted on the loader or is secured so that it will not move if the tire or rim should suddenly fail.

1.11 Do not weld, braze, or otherwise repair a rim, Do not use a damaged rim.

1.12 Never attempt tire repairs on a public road or highway.

1.13 Use jack stands or other suitable blocking to support the loader while repairing tires

1.14 Insure jack has adequate capacity to lift your loader.

1.15 Insure jack is placed on a firm level surface.

1.16 Do not put any part of your body under the loader or start the engine while the loader is on the jack.

1.17 Torque lug nuts to specification after reinstalling wheel. Check lug nut torque hourly until torque stabilizes.

10.00 x 16.5 40-45 PSI (276 - 310 kPa)

2. Tire Rotation

The front and rear tires will wear at different rates. For even wear move the front tires to the rear and the rear tires to the front when wear is first noticed.

If two tires become worn more than the other two put the two worn tires on the same side.

When new tires are installed, always keep tires the same size on the same side of the loader. Two different size tires on the same side of the loader will cause drive chain wear, tire wear and a loss of power

WARNING

To avoid personal injury:

Inflating or servicing

tires can be dangerous.

Trained personnel should

be called to service

and/or mount tires when

possible. In any event to

avoid possible serious or

fatal injury, follow the

safety precautions below.

4. MAINTENANCE

WARNING

NEVER INFLATE

TIRES TO OVER 240

kPa (35 PSI) TO SEAT

BEADS. If beads have not

seated by the time

pressure reaches 240 kPa

(35 PSI), deflate the

assembly, reposition the

tire on the rim,

relubricate both tire

beads, rim flanges and re-

inflate. INFLATION

Beyond 240 kPa (35 PSI)

with unseated beads may

break the bead or rim

with EXPLOSIVE force,

sufficient to cause serious

injury.

TIRE Inflation Pressure

4. MAINTENANCE

4. 13 TROUBLESHOOTING

1. Hydraulic System

Problem Cause Remedy

Loss of hydraulic power (no flow from gear pump)

Loss of hydraulic power (flow from gear pump)

Hydraulic action jerky

Hydraulic System Overheating

Lift arms raise slowly at full engine RPM

Lift or tilt cylinders will not support a load

Hydraulic fluid overheating

Reservoir low on fluid.

Coupling between engine and pump failure.

Spline coupling failure between front and rear hydrostatic pump. Hydraulic gear pump not functioning. Reservoir low on fluid. Auxiliary hydraulics engaged. Relief valve failure in control valve.

Reservoir low on oil. Air in hydraulic system.

Anticavitation check valve not functioning. Engine fan not turning.

Broken hydraulic fluid line.

Reservoir low on oil. Liftarm release valve engaged. Auxiliary engaged. Engine RPM too slow. Anticavitation check valve spring broken. Main relief or port relief valve in control valve faulty. Internal leakage in pump due to wear.

Oil bypassing one or both lift cylinder piston seals. External leak between or at control

valve and cylinders. Control valve spool not centering.

Oil leaking by one or both cylinder piston seals.

Reservoir low on fluid. Oil cooler plugged or dirty (also check engine radiator). Auxiliary engaged.

Add oil and check for leaks.

Inspect and replace damaged parts. Check for misalignment between engine and pumps. Inspect coupling for sheared splines. Also check pump shaft bearings. Inspect and repair. Add oil and check for leaks. Release auxiliary hydraulics. Check pressure and adjust.

Add oil and check for leaks. Check for leak between reservoir and pump. Bleed system by extending and retracting lift cylinders several times. Inspect and repair or replace.

Clean cooling fan and repair or replace. Repair or replace damaged line and add oil. Add oil. Ensure switch is off, valve is closed. Disengage. Check RPM and reset. Replace.

Check pressure, if necessary - adjust.

Check pump flow and repair or replace as necessary. Install new piston seal kits.

Check for leaks and correct.

Pilot hydaulic pressures not even.

Check for broken or stuck return spring on valve spool.

Install new piston seal kits.

Add oil. Clean cooling fins.

Disengage.

4. MAINTENANCE

1. Hydraulic System (Continued) Problem Cause Remedy

Hydraulic fluid overheating (continued) Auxiliary hydraulic does not function.

Engine RPM too slow Incorrect temperature sensor Fuse blown. Solenoid coils on control valve not working. Check valve in control valve not working.

Check RPM and adjust. Replace. Correct fault and replace fuse. Replace

Repair or replace.

2. Hydrostatic Drive Problem Cause Remedy

No power on one side (both directions).

No power on one side (one direction only).

No power on both sides (also loss of hydraulic power).

Gradual loss of power as machine warms up. System erratic and/or noisy.

Machine will not travel in a straight line.

Reservoir low on oil.

Pilot hydraulic line failure. High pressure line failure.

Drive chain failure.

Motor shaft or key failure.

Excessive internal leakage in motor and/or pump.

Defective relief valve. Pilot hydraulic line failure. Reservoir low on oil.

Coupling failure between engine and pump. Brake valve not releasing.

Drive coupling between front and rear pump failure.

Check system pressure.

Excessive internal leakage in pump and/or motor. Air in system due to low oil level in reservoir. Air in system due to leak at suction fitting. Internal pump or motor wear caused by overspeeding. Air in system due to leak at oil reservoir.

Pressure failure in hydraulic pump.

Add oil and check for hose or fitting leak. Replace line. Replace line. Ensure new line fits without being forced. If necessary stress relieve. Replace chain or connection link.

Inspect and repair defective parts. Check motor mounting bolts. Inspect and repair defective unit. Flush all lines and tank. Replace filter. Check on type of fluid used and engine RPM. Replace defective valve. Replace line.

Add oil and check for hose or fitting leak.

Inspect and replace damaged parts.

Repair/replace. Inspect couplings for sheared

splines, replace. Also check support bearings in pumps.

If low contact your

Consult your Thomas

Bleed air from the system and add oil. Check fittings and tighten.

Consult your dealer.SUNBEAR

Check fitting and tighten.

Check and adjust.

dealer.

SUNBEAR dealer.

SUNBEAR

4. MAINTENANCE

4. Control Levers Problem Cause Remedy

Control levers will not center.

Machine operates erratically.

Machine will not travel in a straight line.

Joystick will not center.

Pilot hydraulic line leaking. Failure in hydraulic line.

Pilot hydraulic line leaking.

Adjust or replace.

Replace hydraulic line. Check and repair.

Replace hydraulic line.

3. Final Drive Transmission

Problem Cause Remedy

Final drive transmission noisy

No lubricating oil

Axles have too much end play Parking brake damaged or out af

adjustment Chain loose

Check and bring oil to the proper level.

Check and adjust. Inspect and adjust or replace

damaged parts. Replace the chain.

5. Electrical

Problem Cause Remedy

Engine will not crank over.

Battery failure. Battery cable failure.

Starter failure. Fuse burnt.

Defective relay.

Ignition switch failure.

Check battery - charge or replace. Check for loose or corroded connectors. Tighten and clean as required. Use di-electric grease to prevent corrosion.

Check continuity of cables and replace. Repair or replace.

Check and replace. Check relay continuity. If defective,

replace. Check continuity, repair or replace.

5. Electrical (Continued)

Problem Cause Remedy

Engine cranks over, but will not start.

Loader starts, but hydraulic controls will not release.

Auxiliary hydraulics engaged

Defective glow plug relay.

Defective glow plug.

Broken connection or defective wire.

No fuel. Electric solenoids not releasing

valve.

Engine will smoke, but not run unassisted by starter. Disengage auxiliary hydraulics. Check continuity and if defective, replace. Check continuity and if defective, replace.

Disconnect the ROPS harness from the engine harness. Open the dash panel and check continuity of the circuit not functioning properly in both engine and ROPS harness. Check fuel levels and system.

Defective solenoid or solenoid lock. Loosen screws and readjust. Check continuity of connectors and wire.

4. MAINTENANCE

6. Engine

Problem Cause Remedy

Engine does not start.

No fuel. Air in the fuel. Water in the fuel.

Fuel pipe clogged. Fuel filter clogged.

Excessively high viscosity of fuel or engine oil at low temperature. Fuel with low octane number.

Fuel leak due to loose injection pipe retaining nut.

Incorrect injection timing. Fuel cam shaft worn. Injection nozzle clogged. Injection pump malfunctioning. Seizure of crankshaft, camshaft, piston, cylinder liner or bearing. Compression leak from cylinder.

Improper valve timing. Piston ring and liner worn. Excessive valve clearance.

Replenish fuel. Vent air.

Change fuel and repair or replace fuel system.

Clean. Clean or change.

Use the specified fuel or engine oil.

Use the specified fuel. Tighten nut.

Adjust. Replace. Clean. Repair or replace. Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder. Correct or replace timing gear. Replace. Adjust.

4. MAINTENANCE

6. Engine (Continued)

Problem Cause Remedy

Starter does not run.

Engine revolution is not smooth.

Either white or blue exhaust gas is observed.

Either black or dark gray exhaust gas is observed.

Excessive lubricant oil consumption.

Fuel mixed into lubricant oil.

Water mixed into lubricant oil.

Low oil pressure.

High oil pressure.

Battery discharged. Starter malfunctioning. Key switch malfunctioning. Wiring disconnected. Fuel filter clogged or dirty. Air cleaner clogged. Fuel leak due to loose injection pipe retaining nut. Injection pump malfunctioning. Incorrect nozzle opening pressure. Injection nozzle stuck or clogged. Fuel overflow pipe clogged. Governor malfunctioning. Excessive engine oil. Low grade fuel used. Fuel filter clogged. Air cleaner clogged. Overload. Low grade fuel used. Fuel filter clogged. Air cleaner clogged. Piston rings gap facing the same direction. Oil ring worn or stuck. Piston ring groove worn. Valve stem and guide worn. Crankshaft bearing and crank pin bearing worn.

s plunger worn.Injection pump' Injection pump broken. Head gasket defective. Cylinder block or cylinder head flawed. Engine oil insufficient. Oil strainer clogged. Relief valve stuck with dirt. Relief valve spring weakened or broken. Excessive oil clearance of crankshaft bearing. Excessive oil clearance of crank pin bearing. Excessive oil clearance of rocker arm bearing. Oil passage clogged. Oil pump defective. Different type of oil. Relief valve defective.

Charge. Repair or replace. Repair or replace. Connect. Clean or change. Clean or change. Tighten nut.

Repair or replace. Adjust. Repair or replace. Clean. Repair. Reduce to the specified level. Repair or replace. Adjust. Adjust top clearance. Lessen the load. Use the specified fuel. Clean or change. Clean or change. Shift gap direction.

Replace. Replace. Replace. Replace.

Replace pump element or pump. Replace. Replace. Replace.

Replenish. Clean. Clean. Replace.

Replace.

Clean. Replace. Use the specified oil type. Replace.

6. Engine (Continued)

Problem Cause Remedy

Engine overheated.

Deficient output.

Battery quickly discharges.

Engine oil insufficient. Fan belt broken or elongated. Cooling water insufficient. Radiator net and radiator fin clogged with dust. Inside of radiator corroded. Cooling water flow route corroded. Radiator cap defective. Overload running. Head gasket defective. Incorrect injection timing. Unsuitable fuel used. Incorrect injection timing. Engine' s moving parts seem to be seizing. Uneven fuel injection. Deficient nozzle injection. Compression leak.

Battery electrolyte insufficient. Fan belt slips. Wiring disconnected. Rectifier defective. Alternator defective. Battery defective.

Replenish. Change or adjust. Replenish. Clean.

Clean or replace. Clean or replace. Replace. Loosen the load. Replace. Adjust. Use the specified fuel. Adjust. Repair or replace.

Repair or replace injection pump. Repair or replace nozzle. Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder. Replenish distilled water recharge. Adjust belt tension or charge. Connect. Replace. Replace. Change.

4. MAINTENANCE

P 1

4. MAINTENANCE

4.14 HYDRAULIC / HYDROSTATIC CIRCUIT

Oil Cooler

Return From

Liftarm Lowering

Valve

Hydraulic Gear

Control Valve

Pump

Tandem

Pump

Brake Release Coupler

Oil Filter

Oil Tank

100 Micron Filter

Supply & Return Lines R.H. Control Lever

Torque Motor w/ Brakes

C5346

Torque Motor w/ Brakes

Hydraulic

Control

Lock Valve

Brake Valve

Fig. 4. 12

4. MAINTENANCE

4.14 HYDRAULIC CIRCUIT

Tilt Cylinders

Lift Cylinders

Auxiliary Hydraulics

C5345

Control Valve

A. Lift Cylinder Circuit B. Tilt Cylinder Circuit C. Aux. Hydraulics Circuit

To Oil Cooler

From

Gear

Pump

Supply & Return Lines From Liftarm Valve

Accumulator

Liftarm Lowering

Valve

Return

To Tank

4. MAINTENANCE

4.15 SPECIAL TOOLS

Part #

ILLUSTRATION

DESCRIPTION

OPTION(O/X)

962201

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 3 required

955283

(6 Bolt)

AXLE EXTRACTOR TOOL:

To remove axle from final drive housing.

Qty. 1

960475

(8 Bolt)

AXLE EXTRACTOR TOOL:

To remove axle from final drive housing.

Qty. 1

955287

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 1

960997

CHAIN TENSION TOOL:

To test chain tension.

C3651

C3652

C3653

C3655

C3658

964613

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 2 required

C3657

4. MAINTENANCE

4.15 SPECIAL TOOLS (Cont'd)

Part #

ILLUSTRATION DESCRIPTION

OPTION (O/X)

Universal

Tool Kit

U-1288

UNIVERSAL TOOL KIT:

1 each. Combination wrench 7/16", 1/2", 9/16", 11/16", 3/4", 1 1/16", 1 1/4". Sockets, 1", 1/2" drive, 7/8", 1/2" drive, tool pouch, allen wrench 5/32" and 1/8".

C1840

C1841

CHAIN PULLER

SPANNER -

To Repair Hydraulic Cylinders

PHOTO SENSOR / WHEELSPEED TACHOMETER (Dual Function)

C1837

43979

43980

43981

WRENCH 2" 4 3/4":

4. MAINTENANCE

4.15 SPECIAL TOOLS (Cont'd)

Part #

ILLUSTRATION DESCRIPTION

OPTION (O/X)

MULTI METER:

For measuring continuity, voltage, etc.

ANGLE FINDER:

For measuring control angles, U-joint and chassis angles etc.

C2343

C2342

960456

HYDRAULIC FLOW and

PRESSURE GAUGE ASSEMBLY

NOTES:

5. SPECIFICATIONS

5. 1 Loader Specifications

5. 2 Torque Specifications

5. 3 Decals

5. SPECIFICATIONS

Dimensions: (With Std. Tires & Dirt Bucket)

A. Overall operating height....................................................................................................................... 152.4" (3870mm)

B. Height to hinge pin................................................................................................................................188.4" (3008mm)

C. Overall vehicle height............................................................................................................................. 76.2" (1935mm)

D. Overall length with bucket ................................................................................................................... 135.4" (3438mm)

E. Dump angle ...............................................................................................................................................................42°

F. Dump height ............................................................................................................................................ 91" ( 2311mm)

G. Reach - fully raised ............................................................................................................................... 24.6" (626mm)

H. Maximum roll back at ground ................................................................................................................................. 32.2°

I. Maximum roll back fully raised ............................................................................................................................... 104°

J. Wheel base.............................................................................................................................................. 41.4" (1052mm)

K. Overall length less bucket .................................................................................................................... 106.3" (2699mm)

L. Ground clearance ....................................................................................................................................... 7.7" (195mm)

M. Maximum grading angle-bucket ............................................................................................................................. 92.5°

N. Angle of departure ...................................................................................................................................................... 26°

O. Bucket width .......................................................................................................................................... 63.4" (1610mm)

P. Clearance circle-front-less bucket ......................................................................................................... 51.6" (1310mm)

Q. Clearance circle-front-with bucket ........................................................................................................ 83.3" (2115mm)

R. Clearance circle-rear ............................................................................................................................. 61.75" (1567mm)

S. Overall width-less bucket ....................................................................................................................... 60.5" (1536mm)

T. Tread........................................................................................................................................................... 50" (1270mm)

Operational:

Tipping Load SAE .................................................................................................................................. 3263 lbs. (1480 kg)

Rated Operating Capacity ......................................................................................................................... 1632 lbs. (740 kg)

Operating Weight .................................................................................................................................... 6283 lbs. (2850 kg)

Shipping Weight....................................................................................................................................... 5677 lbs. (2575 kg)

Travel Speed......................................................................................................................................... 6.55 mph (10.54 kph)

5.1 LOADER SPECIFICATIONS

5. SPECIFICATIONS

O T S

Controls

VEHICLE: Steering direction and speed controlled by left control lever. HYDRAULICS: Lift and bucket tilt are controlled by right control lever. Auxiliary hydraulics controlled by electical

switches on right control lever and left dash panel.

ENGINE: Hand throttle lever, key type ignition switch and shutoff.

Engine

Make and model..........................................................................................................................................Cummins A2300T

Cylinder..................................................................................................................................................................................4

Cooling system..............................................................................................................................................................Liquid

Displacement........................................................................................... ...............................................135 cu. in. (2290 cc)

Horsepower (Gross)................................................................................ .............................................................................60

Electrical Power...........................................................................................................................................................44.7kW

Max Torque............................................................................................................................135 ft.lbs. (18.7 kg/m @ 1600)

Fuel Type...............................................................................................................................................................Diesel No.2

Air Cleaner........................................................................................................Dual Replaceable Dry Cartridge w/Indicator

High Idle RPM.................................................................................................................................................................2800

Fuel Tank Capacity.............................................................................................................................................76 L (20 gal.)

Hydraulic System

Pump type ........................................................................................................................................................................Gear

Pump Capacity (theoretical) ................................................................................................................20.1 GPM (76 L/min)

Control Valve..........................................................................................................................................................Series type

Filtration....................................................................................................................................................................5 Micron

Hydraulic Fluid................................................................................................... ...................................................ISO VG 32

Oil Cooler..............................................................................................................................................994 BTU (1050 kCal)

Cylinders. .....................................................................Lift........................................................................Tilt

Type................................................................Double acting.........................................................Double acting

Qty- per mach .........................................................2........................................... ...................................2

Bore dia .........................................................2.55 in (65mm)........................................................2.55 in (65mm)

Rod dia ..........................................................1.57 in (40mm)........................................................1.18 in (30mm)

Stroke ..........................................................27.125 in (689mm)................................................13.375 in (340mm)

Hydrostatic Transmission & Final Drive:

Pump type ................................................................................................. .................................................................Tandum

Pump displacement .......................................................................................... ............................................2.47 in

(41 cm3)

Motor type ...................................................................................................................................................................Geroler

Motor displacement ....................................................................................................................................31.5 in3(523 cm3)

System relief setting ......................................................................................... ........................................5000 PSI (345 bar)

Drive Type ...................................................................................................................................................Two Drive Chain

Drive chain size ..........................................................................................................................................................RS#100

Electrical

Alternator .........................................................................................................................................................................50 A

Battery ..............................................................................................................................................................................12V

Cranking Amps...................................................................................................................................................................680

Starter................................................................................................................................................................12 V (2.0 kW)

Circuit breaker setting .....................................................................................................................................................40 A

5. SPECIFICATIONS

Tires

Standard.................................................................................. ..........10.00 x 16.5, 8 ply rating, 60 PSI (414 kPa)

Fluid Capacities

Fuel Tank...........................................................................................................................................................20 gal. (76 L)

Hydraulic Oil Tank............................................................................................................................................20 gal. (76 L)

Drive Chain Box (each) ...................................................................................................................................2.6 gal. (10 L)

Engine Oil........................................................................................................................................................1.7 gal. (6.5 L)

Engine Cooling System.......................................................................................2.9 gal. (10.2 L), 50/50 water and ethylene

5.2 TORQUE SPECIFICATIONS

Loader

Wheel nuts (24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 - 110 ft lbs. (136 - 139 Nm)s

Torque motor drive sprocket (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ft. lbs.(65 Nm)

Hydraulic / Hydrostatic

Gear pump section bolts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 28 ft. lbs. (34 - 38 Nm)

Piston pump section bolts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 31 ft. lbs. (37 - 42 Nm)

Torque motor section bolts (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ft. lbs. (68 Nm)

Hydraulic filter, case (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ft. lbs. (41 Nm)

5. SPECIFICATIONS

FOR NON-CRITICAL AND NOT OTHERWISE MENTIONED APPLICATIONS. THE FOLLOWING GENERAL ASSEMBLY TORQUES WILLAPPLY:

BOLTS AND NUTS TORQUE SPECIFICATIONS

General Application Only

SAE

METRIC

SAE GRADE 5 TORQUE SAE GRADE 8 TORQUE

ft.lb. (Nm) ft.lb. (Nm) ft.lb. (Nm) ft.lb. (Nm)

DRY LUBRICATED DRY LUBRICATED 1/4 ~ 20 6 (8) 4 (5.5) 9 (12) 6 (8) 1/4 ~ 28 7 (9.5) 5 (7) 10 (13.5) 7 (9.5) 5/16 ~ 18 13 (17.5) 9 (12) 18 (24.5) 13 (17.5) 5/16 ~ 24 14 (19) 10 (13.5) 20 (27) 14 (19) 3/8 ~ 16 22 (30) 16 (21.5) 30 (40.5) 23 (31) 3/8 ~ 24 25 (34) 18 (24.5) 35 (48) 26 (35.5) 7/16 ~ 14 35 (48) 26 (35.5) 45 (61) 34 (46) 7/16 ~ 20 39 (53) 29 (39.5) 55 (74.5) 41 (55.5) 1/2 ~ 13 55 (74.5) 52 (70.5) 75 (101.5) 56 (76) 1/2 ~ 20 60 (81.5) 55 (74.5) 80 (108.5) 59 (80) 9/16 ~ 12 75 (101.5) 57 (77) 110 (149) 80 (108.5) 9/16 ~ 18 85 (115) 63 (85.5) 120 (162.5) 90 (122) 5/8 ~ 11 105 (142) 78 (105.5) 150 (203) 111 (150.5) 5/8 ~ 18 120 (162.5) 89 (120.5) 165 (223.5) 125 (169.5) 3/4 ~ 10 185 (250.5) 139 (188.5) 260 (352.5) 197 (267) 3/4 ~ 16 205 (278) 155 (210) 290 (393) 220 (298)

METRIC CLASS 8.8 TORQUE METRIC CLASS 10.9 TORQUE

ft.lb. (Nm) ft.lb. (Nm) ft.lb. (Nm) ft.lb. (Nm)

DRY LUBRICATED DRY LUBRICATED M6 X 1.00 5 (7) 4 (5.5) --- --M8 X 1.25 13 (17.5) 10 (13.5) 19 (26) 14 (19) M10 X 1.50 27 (36.5) 20 (27) 38 (51.5) 28 (38) M10 X 1.25 28 (38) 21 (28.5) --- --M12 X 1.75 47 (63.5) 35 (47.5) 65 (88) 48 (65) M12 X 1.25 51 (69) 39 (53) --- --M14 X 2.00 75 (101.5) 56 (76) 103 (139.5) 78 (105.5) M14 X 1.50 81 (110) 60 (81.5) --- --M16 X 2.00 116 (157) 88 (119) 161 (218) 121 (164) M16 X 1.50 124 (168) 93 (126) --- --M20 X 2.50 227 (307.5) 170 (230.5) 315 (427) 236 (320) M20 X 1.50 252 (341.5) 190 (257.5) --- --M24 X 3.00 394 (534) 295 (400) 545 (738.5) 408 (553) M24 X 2.00 428 (580) 321 (435) --- ---

5.2 TORQUE SPECIFICATIONS

#41045

#36841

23325

#23325

PULL

31291

LOW

FAST

SPEED

#31291

PUSH

#35886

32275

#32275

23326

#23326

#23324

23324

42107

DL165 1632󰼿lbs󰼿(740󰼿KG)

#42107

39196

SUNBEAR

#39196

#23309

39192

#39192

35866

41066

36598

#35866

#41066

#36598

5.3 DECALS

#23310

23310

46301

#46301

PUSH

LIFT󰼿ARM

DOWN󰼿VALVE

#31292

#39191

39191

#23312

23312

41064

#41064

23308

#23308

#23321

HYDRAULIC

HYRAULICO

HYDRAULISCH

HYDRAULIQUE

#23307

23307

5.3 DECALS

#47265

DL 165

#41065

41065

#25460

25460

DO󰼿NOT󰼿MOVE󰼿LIFT󰼿ARM󰼿WITH

SUPPORTER󰼿ENGAGED

#47264

DL 165

#44615

DL 165

Notes:

6. ATTACHMENTS AND BUCKETS

6. 1 SUNBEAR Approved Buckets and Attachments

6. ATT ACHMENTS AND BUCKETS

Cat. # Description Approx. W eight

941 9" X 48" (228.6 mm x 1219 mm) Auger Bits 75 lbs ( 34 kg ) 943 12" X 48" (304.8 mm x 1219 mm) Auger Bit w/Serrated Edges 100 lbs ( 45.4 kg )

14" X 52" (355.6 mm x 1320.8 mm)Auger Bit w/Serrated Edges 105 lbs ( 47.6 kg )

120 16" X 52" (406.4 mm x 1320.8 mm) Auger Bit w/Serrated Edges 118 lbs ( 53.5 kg )

Post Hole Auger Bits

6. 1 SUNBEAR APPROVED BUCKETS AND A TTACHMENTS

Cat. # Description SAE Heaped Cap. (cu. ft.) Approx. Weight

1955 66" (1676 mm) Snow and Light Material Bucket 23.7 468 lb. (212.3 kg) 2667 66" (1676 mm) Dirt Bucket 12.85 425 lb. (192.8 kg) 2002 68" (1727 mm) Fertilizer Bucket 20.6 396 lb. (179.6 kg) 2007 66"(1676mm)High Capacity Bucket 28.7 495lb.(224.6KG) 3763 66"(1676mm)Produce Bucket

Buckets

Cat. #

Description Approx. Weight

2032

70" (1778 mm) Dozer Blade, Hydraulic Swing (1) 710 lbs. (322 kg)

Dozer Blade

6. A TTACHMENTS AND BUCKETS

Cat. # Description Approx. Weight

1943

Hydraulic Salt/Sand Spreader (1) 394 lb. (178. 7 kg)

Hydraulic Spreader

Cat. # Description Approx. W eight

2569 Model PA40 Auger Drive (Requires Mount and Bit) (1) 160 lb. (72.6 kg) 1891 Auger Mount 126 lb. (57.2 kg)

Post Hole Auger

Bucket Options

(1) Require Quick Coupling Kit

Cat. #

Description

Approx. Weight

2670

oothbar Complete for 66" Dirt Bucket

95 lb. (43.1 kg) 2668 Kit, Bolt-On Edge for 66" Bucket 90 lb. (40.8 kg) 3494

66" Bucket WithWeld On Teeth

3495

68" Bucket,U-1890 With Weld On Teeth

3496

68"Hi-Visib. Bucket,U-3181 With weld on Teeth

Cat. # Description Approx. Weight

1930 60" (1524 mm) Grapple Bucket 875 lb. (369.9kg)

Grapple Bucket

Cat. # Description Approx. W eight

1694 HH 300/500 Side Plates 200 lb. (91 kg) 1891 HH 300/500 Breaker Mount 192 lb. (87.1 kg)

Breaker Side Plates

(1) Require Quick Coupling Kit

119

Cat. # Description Approx. Weight 3349 HH 300-300 lb. Class Hydraulic Breaker (1) (2) 300 lb. (136 kg)

Hydraulic Breaker (REQUIRES SIDE PLATES, MOUNT & TOOL)

Cat. # Description

Approx. W eight

2330 Pallet Fork Frame (Requires Tines) 226 lb. (102.5 kg) 99 30" Tines (Set of Two) 110 lb. (49.9 kg) 98 36" Tines (Set of Two) 138 lb. (62.6 kg) 437 42" Tines (Set of Two) 149 lb. (67.6 kg) 2564 Tines (Set of Two) 160 lb. (72.6 kg)

Pallet Fork

Cat. # Description Approx. W eight

2213 BH 108 Backhoe Base Unit (1) (2) 780 lb. (353.8 kg) 2211 External Controls (1) 470 lb. (213.2 kg) 2222 Internal Controls (1) 470 lb. (213.2 kg) 2234 Mounting Kit (1) 2235 English Manuals and Decals (1) 1 lb. (0.5 kg) 1483 12" Bucket w/Teeth (1) 120 lb. (54.4 kg) 1482 18" Bucket w/Teeth (1) 140 lb. (63.5 kg) 1481 22" Bucket w/Teeth (1) 160 lb. (72.6 kg)

BH 108 Backhoe

(1) Use Of ACab Door Recommended With This Attachment (2) Prices Are FOB Glendale Hts., IL.

(1) Order one each base unit, controls, mount, manual & bucket. (2) Includes flat face quick coupling kit.

6. A TTACHMENTS AND BUCKETS

6. 1 SUNBEAR APPROVED BUCKETS AND ATT ACHMENTS (Continued)

Cat. # Description Approx. Weight

1533 Moil Point - DB10 25 lb. (11.3 kg) 1534 Chisel Point - DB10 35 lbs. (16 kg) 1535 Blunt Point - DB10 35 lbs. (16 kg) 1570 Asphalt Cutter - DB10 41 lbs. (18.6 kg) 1571 T amping Pad, 12" x 12" 105 lbs. (47.6 kg) 1548 Gas Changer 2 lbs. (0.9 kg)

Breaker Tools

Cat. # Description Approx. W eight

2189 72" Brush (Requires quick coupler kit) 500 lbs. (226.8 kg) 2708 Pofit type quick coupler 5 lbs. (2.3 kg) 2873 Flat Face Type Quick Coupler

Bucket Brush

6. A TTACHMENTS AND BUCKETS

6. 1 SUNBEAR APPROVED BUCKETS AND A TTACHMENTS (Continued)

Cat. # Description Approx. Weight

2189 72" Angle Broom (Requires Quick Coupler Kit) 500 lb. (226.8 kg) 2708 Quick Coupler Kit, Poppet Style 5 lb. (2.3 kg) 2873 Quick Coupler Kit, Flat Face Style

Angle Broom

Cat. # Description Approx. Weight

1392 60" Bucket Sweeper Drive (Requires Quick Coupler, Plate, Bucket) 564 lb. (255.9 kg) 1428 72" Bucket Sweeper Drive (Req. CPLR, Plate, Bucket) (1) 660lb. (299 kg) 2708 Quick Coupler Kit. Poppet Style 5 lb. (2.3 kg) 2873 Quick Coupler Kit, Flat Face Style 1427 Backing Plate 5 lb. (2.3 kg) 1935 60" Flat Bottom Utility Bucket 386 lb. (175 kg) 1936 73" Utility Bucket 480 lb. (218 kg)

Bucket Sweeper

Cat. # Description Approx. Weight

1834 Gutter Brush (1) 80 lb. (36.3 kg) 1298 Water Sprinkler System (1) 50 lb. (22.7 kg)

Bucket Sweeper Options

(1) Dealer Assembly Required

INDEX

Accumulator 28 Air Cleaner 33,35,45 Attachments

Installing 16 Lists 74-75

Auxiliary Hydraulics

Connecting 14 Controls 14 Operation 24

Axle 38

Backfilling 23 Battery

Boost 47 Maintenance 37,47

Specification 66 Bearing,Axle 38 Boost Lug 47 Boosting Procedure 47 Brake

Override 41

Parking 12,36

Cab

Maintenance 37

Prop Rod 32

Tilting 32 Chain, Drive 36,38 Control Levers

Lever Function 13,15,36

Switch Function 9 Coolant 35,46

Decals 69,70,71 Digging 22 Dumping, Bucket 21,22

Electrical

Diagram 48-50 maintenance 37 Panel 17

Engine

Oil 30,42 Relay, Preheat 17 Shut-down 20 Specifications 42 Speed 35 Starting 19 V-Belt Tension 43

Exhaust 35

Fan 36 Filters, Replace

Air 45 Engine 42 Fuel 43

Hydraulic Oil 40 Final Drive 38 Foreword 4 Fuel Gauge 8 Fuel System 35,43

Bleeding 44 Fuse Panel 17

Greasing 34

Hoses And Pipes 36 Hour Meter 8 Hydraulic Function 36 Hydraulic/Hydrostastic 36

Circuits 58,59

Motor 36

Oil Filter 36

INDEX

Ignition Switch 8 Indexes, Sections

Section 1 3 Section 2, Controls 7 Section 3, Operation 18 Section 4, Maintenance 29

Section 5, Decals 64 Indicator Lights 8,9 Inspection, Pre-Start 19 Instrument Panel 8,9

Leveling 23 Liftarm

Control 15

Lowering 27

Support 13,32,36 Lifting 25 Lubrication 34,37

Maintenance

Schedule 30

Special Tools 60-62

Oil Cooler 35,36,41 Oil, Engine 30,34,35,36,42

Hydraulic 30,33,36,39,40

Transmission 30,36,38 Operational Procedures 20-24

Pump 36

Quick-Tach 37

Radiator/Oil Cooler 35,41

Safety Precautions 5,6 Seal, Axle 36 Seat 10 Seat Bar 11,36 Seat Belt 36 Seat Switch 36 Service Access 32 Service

Daily 33-35 50 hr 35-37

200 hr 37 Service Schedule 30-31 Shields 37 Shut-off Procedure 20-26 Slopes

Travel on 20

Parkingon 6 Specifications, Loader 65,66,67,68 Sprocket 38

tarter 37

tarting Procedure 19

teering Control 13

Throttle 12,36

ilt Cab 32

ires

Maintenance 51

Pressure 37,51

Rotation 51

owing 25

ransporting 26

roubleshooting 52-57

urning 13-20

-Belt Tension 43

Warranty Statement 2 Water Separator 43 Wheel Nuts 34,37

SunBear DL165H Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual