Hydraulic Oil Cooler. Assembly Instructions (Originating w/serial Number )

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1 Hydraulic Oil Cooler Case 465 Skid Steer Assembly Instructions (Originating w/serial Number ) Model Number: Serial Number: Date of Purchase: Specialized Equipment, Inc. 650 So. Main Street - PO Box Hector, MN Business Phone: * Fax: * Toll Free: N14878 July 2007

2 WARNING Because of the potential safety hazard to eyes from hydraulic leaks and/or flying debris, USE OF PROTECTIVE EYEWEAR IS ABSOLUTELY MANDATORY for operator and others in the work area. Due to the possible danger of flying debris, it is ABSOLUTELY MANDATORY that IMPACT- RESISTANT SHIELDING be provided on the power unit to protect the operator. The owner is responsible for providing the operator protection devices on the power unit. Flying debris can gather on the skid-steer and needs to be cleaned off, especially around the radiator and oil cooler screens, engine compartment and exhaust areas. Periodic cleaning will help prevent the possibility of fire.

3 TABLE OF CONTENTS (LOFTNESS OIL COOLER BTU ON CASE 465) Page Preparing to Install 1 Installing the Cooler Mount.. 2 Attaching the Cooler.. 3 Connecting the Hydraulics 4 Installing the Fan Wire Harness 13 Check and Verify Operation.. 16 Cleaning the Cooler 17 Tilting the Cab for Service. 17 Operation. 18 Cooler Part Identification.. 19 Mount Kit Part Identification. 21

4 PREPARING TO INSTALL: Before you begin the installation, make sure you have the following parts. 1. The oil cooler and protective box. (Refer to pages for a complete listing of parts) 2. The mounting kit. (Refer to pages for a complete listing of parts) 3. The hydraulic kit including hoses and fittings. (Refer to pages for a complete listing of parts) 4. Prepare the work area and skid steer. Your work area should allow you to raise and lock the boom arms on the skid steer. Make sure the skid steer will not have to be moved during installation as the hydraulics will be disconnected. An overhead hoist or lifting device is recommended. Assemble hardware as described but do not completely tighten the hardware until everything is assembled and properly adjusted

5 INSTALLING THE COOLER MOUNT: 5. Prepare skid steer roof for mounting. Clean the roof surface of excess dirt and debris. 6. Remove two plugs from each side of cab near the top and towards the front. These holes will be used for the roof cooler mount. In some cases there may be an optional lifting ring bracket installed in these holes, which will need to be removed to install the cooler brackets. 7. Remove the three bolts near the back of the cab roof. You may need to hold up the air conditioning unit on the inside while you unbolt these three bolts. Add silicone caulk over the three bolt holes (shown) just prior to installing the cooler mount to help seal the roof. 8. Place mount on skid steer roof as shown

6 9. Slide the cooler mount into position over the three roof holes as shown. Add hardware as shown in the exploded view on pages The front of the mounting uses two holes per side as shown. Refer to the exploded view on pages for the proper hardware. ATTACHING THE COOLER: 11. Before lifting cooler onto cab roof, remove bottom screen from cooler. Unscrew wing nuts and slide bottom screen completely out of box. Use two straps and over hoist to lift cooler box as shown. The cooler weight is approximately 220 lbs. Refer to photo for placement of straps for lifting. Top screen shown removed for clarity. 12. With cooler securely strapped to hoist, raise cooler to skid steer roof level and position over the mounts. Note: The hydraulic ports will face towards the rear of the skid steer

7 13. Attach legs of cooler to outside of mounting ears on all four corners using hardware. Refer to exploded view pages for correct hardware. 14. Reassemble bottom screen into position. Tighten all mounting hardware to the proper specs. CONNECTING THE HYDRAULICS: 15. This next section will include routing the hoses, disconnecting and reconnecting the hydraulics. Make sure the skid steer will not have to be started or moved during this phase of the installation. Raise loader arms and engage mechanical lock. Tilt cab forward and engage mechanical lock. Note: The cooler will make the cab heavier to lift. Disconnect battery for safety. 16. The Inlet and Outlet ports are shown looking at the back of the cooler from behind the skid steer

8 17. Add quick coupler halves to the inlet and outlet fittings on the roof cooler. Roof Cooler Outlet: Male Nipple Half Roof Cooler Inlet: Female Quick Coupler Half 18. Assemble the inlet and outlet hoses as shown. Outlet Hose 94 : Fitting Straight, Female Coupler Half Inlet Hose 132 : Fitting 45º, Male Nipple Half The male O-ring end of each fitting goes into the nipple/coupler body. The male JIC end of each fitting goes into the hose. 19. The inlet and outlet hoses will attach as shown. Note: These are locking quick couplers. A notch in the female coupler collar must be in the correct orientation to connect and disconnect the couplers. Once the couplers are properly connected, twist the female collar to lock. 20. IMPORTANT: To raise the cab for service, the inlet and outlet hoses must be disconnected from the oil cooler. Connect the inlet hose nipple into the outlet hose coupler whenever they are disconnected from the oil cooler. This will allow for continued oil flow

9 21. Route the roof cooler inlet and outlet hoses along the inside of the right rear lift upright as shown. 22. Route the longer inlet hose under the skid steer main hydraulic pump and back up the other side next to the hydraulic oil filter (as shown). Route the shorter outlet hose across the top of the hydraulic pump towards the back (as shown). 23. Disconnect hydraulic filter and hose at the connection shown. 24. Top view of disconnected hydraulic filter and original hose (refer to previous photo)

10 25. The fittings shown in the photo at left will be added to the hydraulic oil filter in a step by step progression. The fittings in the photo are in their correct order. Refer to this photo throughout the progression. 26. Add 90º fitting (Female JIC/Male JIC) fitting to filter as shown. 27. Add Tee fitting (Male JIC/Female JIC/Male JIC) to the 90º fitting as shown. 28. Add 90º fitting (Female JIC/Male JIC) fitting to end of Tee fitting as shown. Point the male JIC end down towards the floor

11 29. Attach roof cooler 132 inlet hose (routed earlier) to the male end of the 90º JIC fitting which is pointed downwards. (see photo) 30. Add a straight fitting (JIC-Female/O-ring Male) to the other end of the Tee fitting as shown. 31. Add a check valve to the male O-ring fitting end. Important: The spring end of the check valve goes into the O-ring end as shown. Running the machine with the check valve installed reversed could cause severe damage. There should be an arrow inscribed on the check valve pointing to the rear of the skid steer. 32. Check valve shown installed

12 33. Add Tee fitting (male JIC/male O-ring/male JIC) to the open end of the check valve. The O-ring end of the Tee fitting screws into the check valve. Position the Tee fitting as shown. 34. Add a 90º fitting (Female JIC/Male JIC) to the Tee fitting as shown. Point the male end of the 90º fitting down and to the left side of the skid steer. (refer to photo) 35. Move the existing hose end that was originally connected to the hydraulic oil filter, back and down towards the rear of the skid steer. (see photo) You may have to pull hose from the opposite end to get the hose to slide back far enough. 36. Connect the existing hose end (originally from hydr. filter) to the 90º fitting male end (Female JIC/Male JIC). (See photo) - 9 -

13 37. Add Tee fitting (Male JIC/Female JIC/Male JIC) as shown. 38. Attach the 94 roof cooler outlet hose to the Tee fitting as shown. 39. Add a straight fitting (JIC-Female/O-ring Male) to the other end of the Tee fitting as shown. 40. Add a check valve to the male O-ring fitting end. Important: The spring end of the check valve goes into the O-ring end as shown. Running the machine with the check valve installed reversed could cause severe damage. There should be an arrow inscribed on the check valve pointing to the rear of the skid steer

14 41. Check valve shown installed. 42. Add a 45º fitting (male O-ring/male JIC) to the end of the check valve. The male O-ring end screws into the check valve. A hose will be attached to this 45º fitting a little later in the assembly. 43. Move to the rear of the skid steer near the location of the arrow in the adjacent photo. 44. Locate the hydraulic hose connection at the top of the original skid steer cooler on the left side towards the rear

15 45. Disconnect the 90º hose end from the fitting as shown. 46. Add Tee fitting (Male JIC/Female JIC/Male JIC) as shown. Note: This is a size 12 Tee fitting which is slightly smaller than the size 16 Tee fittings used previously. 47. Connect the 90º end of the existing hose to the Tee fitting as shown. 48. Add straight adapter fitting (female JIC-12/male JIC-16) as shown

16 49. Attach the 90º end of the 34 hose (new) to the straight adapter as shown. Route the 34 hose back through the engine compartment to the 45º fitting on the check valve previously installed. 50. Attach the straight end of the 34 hose to the 45º fitting on the check valve previously installed. (see photo) 51. Double check the fitting and hose layout according to the picture at left. Re-check all the hydraulic connections to make sure they are tight. INSTALLING THE FAN WIRE HARNESS: 52. Route the wire harness from the back of the roof cooler towards the rear, over the air conditioning unit and over to the left side

17 53. Route the wire harness down the left side following the hoses on that side. (see photo) 54. Route the wire harness through the same holes the hoses are using on the left side. 55. Remove the outside hose shield cover on the left side. 56. Once the left outside hose shield cover is removed, continue to route wire harness following the hoses on the left side to the front of the skid steer. The hose shield can be reinstalled once the wire harness is routed

18 57. Route the wire harness with the hoses to the inside of the cab. Drop the wire harness along the left inside of the cab as shown. 58. Remove the foot rest floor and route the wire harness under the seat as shown. The foot rest floor can be re-installed once the wire harness has been properly routed. 59. Route the wire harness to the skid steer wire junction area, just below the fuse box on the left side. 60. Black Wire (Cooler) = Ground Yellow Wire (Cooler) = On/Off Ignition Red Wire (Cooler) = Power Connect the Black Wire (Cooler) to a common ground wire (stud). Connect the Yellow Wire (Cooler) to an ignition switched wire. Protect the yellow wire (Cooler) with an inline 5 amp fuse/holder. Connect the Red Wire (Cooler) to a power (hot) wire (stud). Protect the Red Wire (Cooler) with an inline 30 amp fuse/holder

19 61. You can locate the two new inline fuse/holders (5 amp, 30 amp) inside the fuse box for easy access from inside the cab. CHECK & VERIFY OPERATION: 62. To verify the fan operation, the temp sensor must be by-passed. By-pass the temp sensor by disconnecting it from the green wires of the control box. Reconnect the two green wires (control box) into each other to form a loop. Reconnect the battery. Turn on the ignition key without starting the engine. The roof cooler fan should start after a 30 second delay if the temp sensor is by-passed. Turn ignition switch off. Reconnect the temp sensor. 63. Recheck all the hydraulic connections to make sure they are tightened. Lower cab into the normal operating position. Check that the hoses and electrical wires are not pinched or kinked anywhere. 64. Start engine and function loader arms slowly. Unlock safety lever & lower loader arms to ground. Reconnect the hoses to the roof cooler with the quick couplers. Carefully observe for any hydraulic leaks. Caution: Do not use exposed skin to test for hydraulic leaks. High pressure oil can be injected into the skin. If oil is injected into the skin, seek immediate medical attention as serious side affects and death can occur

20 CLEANING THE COOLER: 65. The bottom screen pulls out for easy cleaning. 66. The top unbolts for access to the fan, fan controller, temperature sensor, check valve and cooler core. 67. The fan and shroud top pivot up for access to the cooler core fins. When cleaning the cooler core, be careful not to bend over the small cooler fins as this will severely affect the cooling capacity. Low pressure water or high pressure air can be used with caution. High pressure water is not recommended. TILTING THE CAB FOR SERVICE: 68. To raise the cab for service, the inlet and outlet hoses must be disconnected from the oil cooler. Additional effort will be required to raise and lower the cab with the added weight of the oil cooler

21 69. IMPORTANT: Connect the inlet hose nipple into the outlet hose coupler whenever they are disconnected from the oil cooler. This will allow for continued oil flow. Note: These are locking quick couplers. A notch in the female coupler collar must be in the correct orientation to connect and disconnect the couplers. Once the couplers are properly connected, twist the female collar to lock. 70. Roof cooler shown with hoses disconnected and cab raised for service. OPERATION: 70. In typical operation, the temp sensor will turn the fan on when the hydraulic oil temperature reaches 140ºF. Once the fan is operating, it will run for 30 seconds in the reverse direction blowing air down and cleaning off the lower screen. After 30 seconds the fan will stop, pause and change direction. Next the fan will run for 10 minutes in the forward direction blowing air up and out through the top. The fan will repeat this cycle every 10 minutes. The temp sensor will turn the fan off if the hydraulic oil falls below ºF

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