OPERATOR INSTALLATION & PARTS MANUAL

Transcription

1 1220/1220HL Mid-Mount Loader OPERATOR INSTALLATION & PARTS MANUAL Complete The Delivery / Warranty Registration Card This Manual Must Be Delivered To The Owner At time Of Machine Delivery. Read and Save This Manual Rev. E May 2014 Printed in the U.S.A. KMW Ltd. 198 N. Hwy 281 Great Bend, Kansas Fax

2 FOREWORD You are now the proud owner of a KMW Loader. This loader is a product of KMW quality engineering and manufacturing. It is made of fine materials and under a rigid quality control system. It will give you long, satisfactory service. To obtain the best use of your loader, please read this manual carefully. It will help you become familiar with the operation of the loader and contains many helpful hints about loader maintenance. It is KMW s policy to utilize as quickly as possible every advance in our research. The immediate use of new techniques in the manufacture of products many cause some small parts of this manual to be outdated. KMW dealers will have the most up-to-date information. Please do not hesitate to consult with them. 1. SAFETY FIRST This symbol, the industry s Safety Alert Symbol, is used throughout this manual and on labels on the front loader itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit. DANGER: WARNING: CAUTION: IMPORTANT: NOTE: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates that equipment or property damage could result if instructions are not followed. Gives helpful information 2

3 SAFETY PRECAUTIONS Most loader equipment accidents can be avoided by following simple safety precautions. These safety precautions, if followed at all times, will help you operate your loader safely. Understand that your safety and the safety of other persons is measured by how you service and operate this loader. Know the position and operations of all controls before you try to operate. Make sure you check all controls in a safe area before starting your work. The safety information given in this manual does not replace safety codes, insurance requirements, federal, state, and local laws. Make sure your machine has the correct equipment required by your local laws and regulations. 1. Read and understand both the tractor and the loader Operator Manuals before using the loader. Lack of knowledge can lead to accidents. 2. It is the loader owner s responsibility to make sure anyone operating the loader reads and understands this manual first before operating the machine. 3. The tractor should be equipped with an approved rollover-protective structure (ROPS) or ROPS Cab and seat belt. Use seat belt as specified by tractor/rops manufacturer. 4. Do not lift or carry anybody on the loader, bucket or attachment. 5. Do not allow bystanders in loader work area. 6. Never allow anyone to get under the loader bucket or attachment or reach through the loader boom when the bucket or attachment is raised. 7. Do not walk or work under a raised loader bucket or attachment unless it is securely blocked and held in position. 8. Use extreme caution when operating on a slope; always operate up and down the slope, never across the slope. 9. Add wheel ballast and/or rear weight to counterbalance tractor/loader for stability at maximum loader capacity. Additional counterweight requirements will vary with loader attachments and equipment application. 10. Move the wheels to the tractor manufacturer s widest recommended settings to increase stability. 11. For better stability, always use a tractor equipped with a wide front axle, never use a tractor equipped with a tricycle type front axle. 12. Move and turn the tractor at low speeds. 13. Never travel at high speeds with bucket loaded. 14. Carry loader boom at a low position during normal operation. 15. Use caution when operating the loader with a raised bucket or attachment. A raised loader changes the center of gravity of the machine and increases the possibility of tip over. 16. Avoid driving over loose fill, rocks, holes, or anything that may be dangerous for loader operation or movement. 17. Avoid overhead wires and obstacles when loader bucket or attachment is raised. Electrocution can occur with or without contact. 18. Check for underground utilities before digging below grade level. 19. Allow for the loader length when making turns. 20. Gradually stop the loader boom when lowering or lifting. 21. Use caution when handling loose or unstable loads. 22. When servicing the loader or leaving operator's seat for any reason, always: A. Lower the loader to ground. B. Turn on Comfort Drive, if equipped C. Apply the parking brake securely D. Shut off the engine E. Turn on tractor switch so Comfort Drive Solenoid is energized. F. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions. G. Return lever or levers to neutral position. H. Turn off tractor switch and remove the key. 23. Operate the loader controls only when properly sitting on the tractor seat. 24. Visually check for hydraulic leaks and broken, missing, or malfunctioning parts. Make necessary repairs before operation. 25. Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Do not use HANDS to search for suspected leaks. If injured by escaping fluid, obtain medical treatment immediately. 26. Before disconnecting hydraulic lines, relieve all hydraulic pressure. 3

4 27. Do not tamper with the relief valve setting. 28. Never use loader for handling large heavy objects, such as large round or rectangular bales, logs, and oil drums unless loader is equipped with attachment that is designed to handle such objects. 29. Handling large heavy objects can be extremely dangerous due to: A. Danger of rolling the tractor over. B. Danger of upending the tractor. C. Danger of the object rolling or sliding down the loader boom onto the operator. 30. If you must handle large heavy objects, protect yourself by: A. Using caution, moving slowly, and avoiding bumps and rough ground. B. Never lifting the load higher than necessary to clear the ground. C. Adding rear ballast to the tractor to compensate for the load. D. Never lifting large heavy objects that may roll or fall on the operator. 31. Operate the tractor and loader such that complete control and machine stability is maintained at all times. 32. Always wear safety goggles when servicing or repairing the machine. 33. When servicing or replacing pins in cylinder ends, bucket, etc., always use a brass drift and hammer. Failure to do so could result in injury from flying metal fragments. 34. Replace damaged or illegible safety labels. See following pages for required labels. 35. Do not modify, alter, or permit anyone else to modify or alter the loader, any of its components, or any loader function without first consulting a KMW dealer. 36. Assemble, remove, and reinstall the loader only as directed in this manual. Failure to do this could result in serious personal injury or death. 37. Never tow from any point of the loader with a chain, rope, or cable. Doing so could cause a roll over or serious damage to the loader. 38. Never lift any load from any point of the loader with a chain, rope, or cable unless loader is equipped with a KMW factory approved attachment which was designed and built for this type of lifting. Always follow lifting instructions included with these attachments. 39. When a front loader is mounted on the tractor, enter and exit the operator s seat only from left side of tractor. 40. Always park loader with a KMW attachment attached to the loader. 41. Special care should be taken to park or store attachments with points or sharp edges in a safe manner. 42. Make sure all parked loaders are on a hard level surface. Engage all safety devices to prevent loader from falling and being damaged or injuring someone. Do not repair loader if it is not mounted on the tractor. Loss of hydraulic fluid or removal of parts could cause loader to collapse resulting in injury. 43. Before starting engine, be sure all operating controls are in neutral or park lock position. 44. When using remote hydraulic tractor valves on some tractors, the loader lift and dump cylinders will continue moving unless the control lever/levers are manually returned to neutral, or until relief pressure is reached at the ends of piston strokes. Observe the bucket or attachment movement and maintain control with the lever/levers. 45. Be certain lights and safety markings as provided by the tractor manufacturer are clean and operating when transporting the tractor/loader on public roads. Be certain that the Slow Moving Vehicle (SMV) emblem is visible. Check with local law enforcement for specific requirements. 46. When using a loader be alert of bucket or attachment position at all times. Loader in raised position with attachment rolled back can dump material onto tractor causing damage or injury to tractor and/or operator. 47. The loader may shift during shipping and handling, making it unstable on the pallet. Support loader with an overhead hoist or other suitable means prior to removing bands or attaching straps securing loader to pallet. Failure to do so could result in accidental tip-over of the loader that could cause serious injury to you and/or bystanders. 48. Do not service the loader while the tractor engine is running. 49. Do not use the loader to raise the tractor in order to perform service on the tractor and/or the loader. 50. Always turn on Accumulator (Comfort Drive), lower loader/attachment to ground and relieve hydraulic pressure from system, before servicing unit. Failure to follow these instructions could result in personal injury. 51. Do not operate without confirmation that coupler pins are fully engaged. Loader attachment can fall off if not properly attached. To avoid serious injury or death: A. Only use loader manufacturer approved attachments. B. Read all operators manuals and decals before operating. Follow all safety operating, and service instructions. Contact dealer for replacement parts. 52. Never turn comfort drive on while tractor is moving. Loader movement could cause loader to lower causing attachment or material being moved to contact ground. Failure to follow these instructions could result in personal injury or property damage. 4

5 SAFETY DECALS Located on the loader hose cover. Located on Accumulator Mounting Plate. See Comfort Drive Section. 5

6 SAFETY DECALS Safety Decal Locations Important: Safety decals , , , and are located on the loader LH side and are visible as you mount the tractor. Important decal is located on LH center mount bracket assembly Warning decal is Located on Quick Attach. Care of Safety Decals 1. Keep safety decals clean and free of obstructing material. 2. Clean safety decals with soap and water and dry with a soft cloth. 3. Replace damaged or missing safety decals with new decals from your KMW Dealer. 4. If a component with a safety decal(s) affixed is replaced with a new part, make sure new safety decal(s) are attached in the same location(s) as the replaced components. 5. Mount new safety decals by applying on a clean dry surface and pressing air bubbles to outside edges. 6

7 TABLE OF CONTENTS 1. INTRODUCTION LIMITED WARRANTY STATEMENT ITEMS NOT COVERED UNDER WARRANTY WARRANTY RESPONSIBILITIES SPECIFICATIONS SPECIFICATIONS OF LOADER BUCKET SPECIFICATIONS INSTALLATION INSTRUCTIONS TRACTOR PREPARATION INSTALLATION CONNECT HYDRAULIC HOSES TO LOADER HOSE CIRCUITS LOADER INSTALLATION PRE-OPERATION INSTRUCTIONS TRANSMISSION FLUID INITIAL LOADER OPERATION EXTERNAL LOADER AND/OR TRACTOR VALVE LOADER MOUNTED CONTROL VALVE EQUIPPED WITH SINGLE LEVER CONTROL HANDLE or TRACTOR REMOTE VALVE EQUIPPED WITH SINGLE LEVER CONTROL HANDLE TRACTOR REMOTE VALVE EQUIPPED WITH 2 OR 3 CONTROL HANDLES NEUTRAL POSITION FLOAT POSITION REGENERATIVE DUMPING POSITION RELIEF CARTRIDGE LOAD SENSE LOADER VALVE INITIAL LOADER OPERATION REMOVING AIR FROM HYDRAULIC SYSTEM RELIEF NOISE HOSE IDENTIFICATION BUCKET LEVEL INDICATOR DAILY MAINTENANCE & LUBRICATION DAILY CHECKS LOADER LUBRICATION LOADER EQUIPPED WITH OPTIONAL GRILL GUARD SKID STEER QUICK ATTACH LUBRICATION Park bucket or attachment OPERATING INSTRUCTIONS FILLING THE BUCKET CARRYING THE LOAD DUMPING THE BUCKET LOWERING THE BUCKET OPERATING WITH FLOAT CONTROL LOADING FROM A BANK PEELING AND SCRAPING LOADING LOW TRUCKS OR SPREADERS FROM A PILE BACKFILLING HANDLING LARGE HEAVY OBJECTS BACK GRADING PROHIBITED OPERATIONS DISMOUNTING THE LOADER MOUNTING THE LOADER SKID STEER TOOL CARRIER SYSTEM RECOMMENDED LOADER FACTORY APPROVED ATTACHMENTS NON-LOADER FACTORY ATTACHMENTS SKID STEER TOOL CARRIER SYSTEM SERVICE & LUBRICATION INSTALLATION & OPERATION OF SKID STEER TOOL CARRIER SYSTEM INSTALLATION INSTRUCTIONS SKID STEER TOOL CARRIER HANDLES IN DISENGAGED POSITION SKID STEER TOOL CARRIER HANDLES IN ENGAGED POSITION INSTALLING BUCKET OR ATTACHMENT TO SKID STEER TOOL CARRIER OPERATING INSTRUCTIONS REMOVING BUCKET OR ATTACHMENT FROM SKID STEER TOOL CARRIER OPERATING INSTRUCTIONS SKID STEER BUCKET SKID STEER BUCKET INSTALLATION INSTRUCTIONS TO SKID STEER TOOL CARRIER SKID STEER BALE SPEAR SKID STEER BALE PROBE ASSEMBLY INSTRUCTIONS INSTALLATION INSTRUCTIONS TO SKID STEER QUICK ATTACH OPERATING INSTRUCTIONS SKID STEER PALLET FORK SKID STEER PALLET FORK ASSEMBLY INSTRUCTIONS INSTALLATION INSTRUCTIONS TO SKID STEER QUICK ATTACH

8 18.4. OPERATING INSTRUCTIONS PARKING INSTRUCTIONS OPTIONAL ORIFICE KIT OPTIONAL ORIFICE KIT LEAK DOWN INSPECTION FRONT END LOADER FIELD LEAK DOWN INSPECTION AND TEST LEAKAGE TEST FOR LIFT CYLINDER SEALS (Open Center Systems) LEAKAGE TEST FOR LIFT CIRCUIT LOADER VALVE SPOOL LEAKAGE TEST FOR TILT OR BUCKET CYLINDER, SEALS TILT OR BUCKET CYLINDER VALVE SPOOL LEAKAGE ACCEPTABLE LIFT CYLINDER LEAK DOWN RATES ACCEPTABLE TILT OR BUCKET CYLINDER LEAK DOWN RATES TROUBLE SHOOTING PROCEDURES TROUBLE SHOOTING FOR ALL LOADERS TROUBLE SHOOTING OPTIONAL LOADER VALVE TROUBLE SHOOTING OPTIONAL COMFORT DRIVE TORQUE CHART PARTS MANUAL BOOM ASSEMBLY HYDRAULIC CYLINDERS, HOSES, AND TUBELINES LIFT CYLINDER (CROSS) TILT CYLINDER (BAILEY) MID MOUNT COUPLER KIT LOADER VALVE 2 SPOOL (Load Sense) LOADER VALVE 2 SPOOL (Open/Closed Center) JOYSTICK CONTROLLER SKID STEER BUCKET LOADER VALVE CONTROL HANDLE COMPONENTS SKID STEER TOOL CARRIER ATTACHMENT SKID STEER BALE SPEAR BUCKET LEVEL INDICATOR SKID STEER PALLET FORK OPTIONAL ORIFICE KITS DECALS & MANUALS NOTES: 8

9 1. INTRODUCTION This manual provides safety, set-up, operation, maintenance, removing, storing, and reinstalling instructions for your new mid-mount loader. Your loader has been designed to give many years of satisfactory service. Successful operation and long life of the loader depends, of course, on proper operation and care. Please read this manual carefully and follow the instructions. Correct operation and maintenance will save much time and expense. OBSERVE and follow all CAUTION, WARNING, and DANGER instructions to help prevent personal injury and damage to the loader. The reference to left hand and right hand used in this manual refers to the position when standing at the rear of the unit and facing forward. If, at any time, you have a service problem with your loader or need new parts, contact your local KMW dealer. Your dealer will need the loader model number and serial number to give you prompt, efficient service. The serial number plate is located on the inside plate of the left hand bearing box. MODEL NUMBER SERIAL NUMBER DATE OF PURCHASE NAME OF DEALER KMW LOADER 9

10 2. LIMITED WARRANTY STATEMENT KMW Ltd., herein referred to as KMW, warrants each new KMW product to be free from defects in material and workmanship. This warranty is applicable only for the normal service life expectancy of the product, not to exceed 12 consecutive months for all hydraulic components and loader attachments and 24 consecutive months on all other loader components from the date of delivery of the new KMW product to the original purchaser. Genuine KMW replacement parts and components will be warranted for 90 days from date of purchase, or the remainder of the original equipment warranty period, whichever is longer. Under no circumstances will it cover any merchandise or components thereof, which, in the opinion of the company, has been subjected to misuse, unauthorized modifications, alteration, an accident or if repairs have been made with parts other than those obtained through KMW. Additionally, the warranty shall only be effective if the owner/dealer responsibilities contained herein are adhered to. The company in no way warrants tractors, engines, batteries, tires or other trade accessories since these items may be warranted separately by their respective manufacturer and are not manufactured by KMW. Our obligation under this warranty shall be limited to repairing or replacing, free of charge to the original purchaser, any part that, in our judgement, shall show evidence of such defect, provided further that such part shall be returned within thirty (30) days from date of failure to KMW routed through the dealer from whom the purchase was made, transportation charges prepaid and the other conditions hereof are complied with. This warranty shall not be interpreted to render KMW liable for injuries or damages of any kind or nature to person or property. This warranty does not extend to the loss of crops, loss because of delay in harvesting, or any expense or loss incurred for labor, substitute machinery, rental or for any other reason. Except as set forth herein, KMW shall have no obligation or liability of any kind on account of any of its equipment and shall not be liable for special or consequential damages. KMW makes no other warranty, expressed or implied, and, specifically, KMW disclaims any implied warranty or merchantability or fitness for a particular purpose. Some states or provinces do not permit limitation or exclusions of implied warranties or incidental or consequential damages, so the limitations or exclusion in this warranty may not apply in those areas only. This warranty is subject to any existing conditions of supply, which may directly affect our ability to obtain materials or manufacture replacement parts. KMW reserves the right to make improvements in design or changes in specifications at any time, without incurring any obligation to owners of units previously sold. No one is authorized to alter, modify or enlarge this warranty nor the exclusion, limitations and reservations. Other restrictions, conditions and responsibilities with respect to the warranty are set forth in the following pages and are fully applicable to the warranty herein provided. 10

11 3. ITEMS NOT COVERED UNDER WARRANTY This warranty only covers those items listed on warranty statement and does not include, among other things, the following: 1. Loaders that warranty registration has not been completed and returned within 10 days of retail sale. 2. Travel time, mileage, meals and lodging. 3. Overtime premiums. 4. Labor time for phone, fax or other consultation between dealers, sales or service management personnel, operators, owners, etc. 5. Replacement of hydraulic oil or steam cleaning product after oil leaks. 6. Any problems related to the mechanical or physical failure of the tractor. 7. Reimbursement for rental units while repairing warranty items. 8. Normal installation and/or pre-delivery procedures, including mounting, lubricating, tightening bolts, fittings, hoses and clamps and maintaining oil levels. 9. Dealer rework due to faulty repair or installation. 10. Bent bucket cylinder rods. 11. Valve spool sticking or leakage caused by contaminated oil. 12. Hydraulic cylinder head cap damage caused by external forces applied to end of cylinder head. 13. Damage or malfunctions resulting from natural calamity, theft, accident, vandalism, abuse due to misapplication, improper site conditions, incorrect maintenance, negligence, unauthorized modifications and/or alterations. 14. Normal maintenance items such as: adjustments, oil changes, lubricating and tightening of bolts, fittings, hoses, and clamps. 15. Parts that engage or contact the working material or normal wearing parts, such as bucket teeth and blade cutting edges. 16. Repair by other than an authorized dealer of the distributor. 17. Switching mounts from one prime mover to another. 18. Exceeding the maximum hydraulic pressure setting from the factory. 19. Alterations or modifications made without express written consent by the distributor or manufacturer. 20. Use of non-factory attachments and parts, attachments and parts made up or purchased from sources other than distributor or manufacturer. 21. Shipping costs other than normal ground transportation. 22. Warranty work completed after 30 days from failure. 23. Claims submitted after 15 days from repair. 24. Claims made under fraudulent situations. 11

12 4. WARRANTY RESPONSIBILITIES The warranties provided herein shall only apply when: Owner Responsibilities 1. Following safety procedures and guidelines as described in the Operator's Manual. 2. Performing all normal and preventive maintenance. 3. Lubrication of machine as specified in operator s manual. 4. Keeping all bolts torqued to specifications. 5. Keeping all safety equipment installed and in working condition. 6. Keeping all filters clean. 7. Repairing all minor hydraulic leaks, such as loose hoses and fittings. 8. Replacing any decals that may be damaged or illegible. 9. Operating the unit only in a safe manner. 10. Using qualified operators who have read and thoroughly understand the operator s and safety manuals. 11. Operating within unit design specifications. 12. Reporting all accidents to the distributor. 12

13 5.1. SPECIFICATIONS OF LOADER 5. SPECIFICATIONS MODEL 1220/1220 HL 45 HP to 80 HP Tractors D E J A B C MODEL HL A. Maximum Lift Height to Pivot Pin.10 4 (124").10 9 (129 ) B. Maximum Lift Height under Level Bucket...10' 10" (130") (135 ) C. Clearance with Bucket Fully Dumped.8 2 (98") 8 5 (101 ) D. Reach at Maximum Lift Height E. Maximum Dump Angle F. Reach with Bucket on Ground. 6 1 (73").6 11 (83 ) G. Maximum Rollback Angle H. Digging Depth J. Overall Height in Carry Position U. Lift Capacity to Maximum Height at Pivot Pin without Self Leveling 3609# # V. Lift Capacity to Maximum Height 31.5" Forward of Pivot Pin without Self Leveling..2406# # W. Lift Capacity to 59" Height at Pivot Pin.5190#... X. Lift Capacity to 59" Height 31.5" Forward of Pivot Pin 3756#... Y. Breakout Force at Ground Line at Pivot Pin.5340# # Z. Breakout Force at Ground Line 31.5" Forward of Pivot Pin # # VV. Rollback Force at Maximum Height 31.5" Forward of Pivot Pin without Self Leveling 3590# # VV. Rollback Force at Maximum Height 31.5" Forward of Pivot Pin w/ Hydraulic S/L # # XX. Rollback Force at 59" Lift Height 31.5" Forward of Pivot Pin 4970# # ZZ. Rollback Force at Ground Line 31.5" Forward of Pivot Pin 3700# # PSI 2950 psi psi Lift Cylinder Diameter " Tilt Cylinder Diameter " Specifications taken with 72" Skid Steer Bucket. Specifications based on ASAE standards S301.3 and furnished for general information only as they can vary with different tractor models. Specifications are subject to change without notice and without liability therefore BUCKET SPECIFICATIONS STRUCK CAPACITY RATED CAPACITY 72 Skid Steer Standard Capacity Bucket cu. yd cu. yd. 78 Skid Steer Standard Capacity Bucket cu. yd cu. yd. 84 Skid Steer Standard Capacity Bucket cu. yd cu. yd. F H G 13

14 6. INSTALLATION INSTRUCTIONS CAUTION: Equip your tractor with a ROPS cab or frame for your protection. See your tractor/rops Operator Manual for correct seat belt usage. Read entire instructions before beginning to install the loader. Personal injury and machine damage may be prevented if you read and understand these instructions and special safety messages. When you are in the tractor seat looking forward, the right and left hand sides of the tractor and loader are the same as your right and left hand TRACTOR PREPARATION Tractor Front Tires Use front tires of equal size and maintain equal pressure in each tire. The pressure of the front tractor tires must be increased to the maximum approved pressure recommended by the tire manufacturer to compensate for additional load placed on the tires with the Front End Loader. See your tractor Operator Manual. Adjust the front tires to the widest recommended setting on adjustable models for maximum stability. Front end weights must NOT be used while loader is on the tractor. Pay particular attention to minimum tread settings information in Installation Instructions included with your Mounting Kit Tractor Rear Tires Maintain equal pressure in each of the rear tires. Use the widest recommended rear wheel setting for maximum stability. 14

15 Recommended Rear Tractor Ballast CAUTION: To help prevent rollover, use recommended rear tractor ballast and widest wheel settings to maximize stability. See your tractor Operator Manual and information on the following ballast. Rear tractor ballast is required after installation of loader on the tractor. Following is recommended ways to ballast your tractor. Install factory rear wheel weights to tractor. Install a calcium solution in rear tractor tires. Install a weight box to tractor 3-point see optional attachments section in this manual. Install some type of 3-point attachment to tractor. Install a backhoe to the tractor. NOTE: You may need to use one or a combination of the above rear ballast methods depending on your tractor and loader application. To check if your tractor is properly ballasted you should conduct the following rear axle weight check. With 1800# installed in 72 bucket, 1900# in 78 bucket or 2100# in 84 bucket. With operator in tractor. With bucket/loader pivot pin positioned as shown in fig. 1. With ballast installed on rear of tractor. Weigh total vehicle weight. Weigh rear axle of tractor. Tractor rear axle must weigh a minimum of 25% of total weight of unit. Example: If total weight of unit = 10,000#, rear axle weight needs to be 2,500# or greater. Ballast Installed With weight above installed in your Bucket with Bucket Pivot level with Boom Pivot Bucket Pivot Boom Pivot Level 12 Fig. 1 Rear Axle should weigh a minimum of 25% of total tractor weight CAUTION: To allow proper steering of the tractor always remove 3-point weight from tractor when the loader is parked from the tractor. Never operate the unit with the loader parked and the backhoe installed. Failure to follow these instructions could cause loss of tractor steering causing personal injury and damage to property. Front tractor weights must only be used when the loader is parked. Weights must be removed before remounting loader or serious damage will occur to loader or tractor front axle due to excessive weight. The use of adequate rear counterweight to counterbalance for maximum loader capacity is required for safe loader operation. Weight added to the rear of the tractor provides better traction and easier, more efficient loader operation. IMPORTANT: Do not exceed the maximum load capacity of the tires on your tractor. See Tire and Wheel Specifications in tractor Operator Manual for more information. NOTE: Rear tractor ballast must be added equally to tractor to allow loader bucket to set parallel to the ground. After installation, check that the tire pressure is equal and the center of rear axle off of ground is equal from right to left side of tractor. This inspection must be completed on a hard level surface. 15

16 6.2. INSTALLATION WARNING: To avoid serious injury or death: Read before cutting bands or removing attaching straps. The loader may shift during shipping and handling, making it unstable on the pallet. Support loader with an overhead hoist or other suitable means prior to removing bands or attaching straps securing loader to pallet. Failure to do so could result in accidental tip-over of the loader that could cause serious injury to you and/or bystanders Position the tractor on a hard level surface. IMPORTANT NOTICE This loader has both standard and metric fasteners. Verify that the proper fasteners are placed in the correct locations. Do not tighten any bolts firmly until all components are attached onto the tractor Install mounting brackets on tractor as shown in Installation Instructions included with your Mounting Kit Tighten all bolts equally during installation so that outside surface of brackets are level and the center line measurement from right hand to left hand mounting brackets reads plus or minus 1/4" as shown at right. IMPORTANT: To prevent mounting kit hardware from loosening during operation always torque mounting kit hardware to specified torque noted in Loader Operator Manual Remove all loader components from shipping packaging. CAUTION: Lift and support all loader components safely. Model 1220/1220 HL X = 42 16

17 6.3. CONNECT HYDRAULIC HOSES TO LOADER HOSE CIRCUITS Install color ties to both ends of remote and/or valve hoses to be connected to loader hoses, matching colors on each end Install hose protector over these hoses Connect these hoses to loader hoses matching color ties then tighten these fittings. Loader Hose Protector Loader Hoses Mark both ends of Hoses using Color Ties before Installation Install Remote and/or Valve Hoses Install Hose Protector Install S-hook as shown to loader hoses using plastic tie strap and dimensions provided if not installed at factory After installing S-hook to hoses using nylon tie, bend nylon tie end of S-hook closed with pliers to prevent S-hook from detaching from hoses. Bend S-hook closed with pliers Note: 1220 HL loader on some tractor models will not use S-Hook. 17

18 Secure hoses by hooking S-hook to quick coupler mount tab on RH center bracket as shown if connected to tractor valve or tractor remotes. Quick Coupler Mount tab S-Hook Secure hoses by hooking S-hook to valve mount if connected using KMW valve. Valve Mount S-Hook Note: 1220 HL loader on some models will not use S- Hook. 18

19 6.4. LOADER INSTALLATION Before installing loader to tractor, install quick attach to loader if Factory has not pre-installed it Secure quick attach to loader with 1 x 4.44 pins, 4 places. Secure each pin using carriage bolt, hardened flatwasher, and stover locknut. Quick Attach Flatwasher 3/8" Hardened, 4 places Acorn Locknut 3/8"- 16NC, 4 places Carriage Bolt 3/8"- 16NC x 1" Grade 5, 4 places (not visible in photo) Pin 1" x 4.44", 4 places CAUTION: Lift and support all loader components safely. IMPORTANT: Do not extend tilt cylinders without quick attach pinned to loader. Failure to follow these instructions could cause loader damage and void warranty Before installing loader to tractor, use a hoist to install quick attach bucket on loader quick attach. See Quick Attach Operation Instructions Section Following these instructions will add stability to loader package and will allow easier handling of loader with hoist Verify that all mounting kit hardware has been torqued as specified before installing loader. A. Identify hardware size and grade. B. Refer to Torque Chart, page 67 and find correct torque for your hardware size and grade. C. Torque hardware to this specification unless otherwise specified. IMPORTANT NOTE: To prevent mounting kit hardware from loosening during loader operation always torque mounting kit hardware to specified torque Support the loader by using a hoist. Refer to Section 11 Mounting the Loader, starting on page 39. Install loader to mounting brackets previously installed on tractor. 19

20 Quick connect loader hoses to hydraulic circuit of tractor previously installed per instructions with Hydraulic Kit installed Photo "A" shows loader hoses connected to Optional Mid-Mount Coupler Kit. Loader Hoses Color Ties Connect Circuits { Color Ties Remote/Valve Hoses Photo "A" 20

21 7. PRE-OPERATION INSTRUCTIONS 7.1. TRANSMISSION FLUID Check the tractor hydraulic fluid level and fill, if required INITIAL LOADER OPERATION NOTE: Keep engine speed at low idle during the initial loader operation. CAUTION: Escaping hydraulic fluid under pressure can have sufficient force to penetrate skin, causing serious personal injury. Before disconnecting lines, be sure to relieve all pressure. Before applying pressure to system, be sure all connections are tight and that lines, tubes, and hoses are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately. (1) Hydraulic line. (2) Cardboard. (3) Magnifying glass EXTERNAL LOADER AND/OR TRACTOR VALVE CAUTION: When properly installed, the tractor remote valve or external valve control lever/levers will control the loader hydraulic circuits as described on pages 21 and 22. Refer to tractor Operator Manual for further explanation of tractor remote control lever/levers. IMPORTANT: Contaminants in hydraulic fluid can cause valve spools to stick. BE ALERT when operating loader and follow your tractor Operator Manual hydraulic fluid maintenance schedule LOADER MOUNTED CONTROL VALVE EQUIPPED WITH SINGLE LEVER CONTROL HANDLE or TRACTOR REMOTE VALVE EQUIPPED WITH SINGLE LEVER CONTROL HANDLE If your loader utilizes a loader mounted control valve equipped with single lever control handle or tractor remote valve equipped with single lever control handle, it will function as described at right. Number 1 Position: Pull the joystick back to raise loader. Number 2 Position: Push the joystick forward to lower loader. Number 3 Position: Push the joystick full forward to activate float position. Number 4 Position: Push the joystick outward to dump attachment (Note A) Number 5 Position: Pull the joystick inward to roll back attachment. NOTE A: KMW ROPS valve has Regen function incorporated in valve. Some tractor loader valves also have this function incorporated in them. See regen section 7.8 for detailed operation information. 21

22 7.5. TRACTOR REMOTE VALVE EQUIPPED WITH 2 OR 3 CONTROL HANDLES Tractor remote valve equipped with 2 or 3 control handles will function as described at right NEUTRAL POSITION The loader external valve provided by KMW has a neutral position which prevents movement of the loader or attachment. When the control handle is manually released from the work position, the valve spool will return to the neutral position FLOAT POSITION The loader external valve provided by KMW has a float position incorporated into the lift cylinder circuit which allows the loader to float. This float feature is important for satisfactory operation when scraping, sweeping, leveling, or any job where it is necessary to follow the contour of the surface. To activate the float position, lower the bucket or attachment and push the control handle all the way forward into detent. The valve will stay in float detent position until the operator manually pulls the control handle out of detent position to deactivate float. IMPORTANT: If the bucket or attachment does not operate as indicated on the directional decal, lower the bucket to the ground, stop the engine, and relieve all hydraulic pressure. Recheck hydraulic circuit hookup to loader valve and correct REGENERATIVE DUMPING POSITION Your valve is equipped with a regen position in the bucket circuit. When digging with the loader, feather the loader valve control handle outward to angle the bucket forward and put the weight of the tractor on the cutting edge. If you position the loader valve into regen position, weight of the tractor may not remain on the cutting edge. The loader valve has a Regenerative Spool incorporated in the attachment spool. The tilt cylinders must be connected to this spool allowing the operator to choose normal dump or fast dump during loader operation. While using regen position some oil will bypass over relief which could cause a small amount of hose chatter and hydraulic relief noise which is normal to operation. NOTE: Regen position will speed up dump operation in most applications. However, operator may not see significant speed increase at high RPM due to some oil being forced over loader valve relief. Use of regen position will eliminate bucket cylinder cavitation. NOTE: Use normal dump position when digging with loader. This will allow operator to put full tractor weight on cutting edge during this operation. The regenerative function can then be used when dumping load from bucket. NOTE: Valve circuits must be hooked up correctly to allow regen to operate correctly. IMPORTANT: If the bucket or attachment does not operate as indicated on the directional decal, lower the bucket to the ground, stop the engine, and relieve all hydraulic pressure. Recheck hydraulic circuit hookup to loader valve and correct. NOTE: Use of regen function during dumping will eliminate attachment cylinder cavitation, which will reduce or eliminate any free movement of bucket or attachment during loader operation. CAUTION: Do not tamper with relief valve setting. The relief valve is pre-set at the factory. Changing the setting can cause overloading of the loader and tractor, which may result in serious injury. 22

23 7.9. RELIEF CARTRIDGE CAUTION: If your KMW valve is equipped with a relief cartridge, do not tamper with the relief valve setting. The relief valve is pre-set at the factory. Changing the setting can cause overloading of the loader and tractor, which may result in serious injury LOAD SENSE LOADER VALVE IMPORTANT NOTE: If your loader is equipped with a load sense type control valve it may demonstrate the following operation characteristic. To raise the boom while finely feathering the control lever may allow the boom to lower very slowly, move the control lever far enough that the boom raises INITIAL LOADER OPERATION Before operating the loader, fully raise and lower the boom two or three times. Then raise the loader bucket approximately four (4) feet above the ground and cycle the bucket cylinders two or three times. Lower the bucket or attachment to the ground. Check the tractor hydraulic fluid level and fill as required. Refer to the tractor Operator Manual for the proper hydraulic fluid and the correct hydraulic fluid level. CAUTION: When servicing the loader or leaving operator's seat for any reason, always: Lower the loader to ground. Turn on Comfort Drive, if equipped Apply the parking brake securely Shut off the engine Turn on tractor switch so Comfort Drive Solenoid is energized. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions. Return lever or levers to neutral position. Turn off tractor switch and remove the key. IMPORTANT: Always keep the cylinders in a retracted position when the loader is not in use to guard against rust and contamination which may cause damage to the cylinder rods and hydraulic system. IMPORTANT: Engage plus handle lever lock in locked position when tractor/loader is being driven on long distances and the loader does not need to be moved. Always engage this lock when dismounting the tractor REMOVING AIR FROM HYDRAULIC SYSTEM Repeat raising and lowering the loader boom and bucket operations until all the air is removed from the system and the system responds properly RELIEF NOISE When operating loaders at high RPMs with optional orifice installed in attachment circuit, some hydraulic oil will go over loader valve relief. This could cause some relief noise from valve, which is normal HOSE IDENTIFICATION Check if loader functions as shown and described on pages 21 and 22. Then install colored nylon ties, one color per each circuit. Locate nylon ties so one is attached to male side of quick coupler and one is attached to female side of quick coupler. This will allow easy identification of loader circuits when mounting and dismounting loader. 23

24 7.15. BUCKET LEVEL INDICATOR Remove allen head plug from right hand tilt cylinder base. Remove allen head plug from right hand tilt cylinder rod. Remove Allen Head Plugs Remove allen head plugs from RH Bucket Cylinder base and rod end Install bucket level indicator rod assembly into bucket level indicator tube assembly Remove allen head plug from cylinder base end. Attach bucket level indicator tube assembly to base end of RH tilt cylinder using 1/4 x 1/2" hardware Remove allen head plug from cylinder rod end. Attach bucket level indicator rod assembly to rod end RH tilt cylinder using 1/4" x ½ hardware Adjust bucket level tube for proper alignment with bucket level rod by sliding slotted bracket to desired position and tightening bolt. Hex Bolt 1/4"-28 x ½ Grade 5, 1/4" Lockwasher, and 1/4" Flatwasher Painted Rod End Bucket Level Indicator Tube Assembly Bucket Level Indicator Rod Assembly Hex Bolt 1/4"-28 x ½ Grade 5, ¼ Flatwasher and 1/4" Lockwasher After installing loader on tractor, position loader on ground with bucket flat, then paint or mark end of bucket level indicator rod so operator can identify when bucket is level on ground. 24

25 8.1. DAILY CHECKS 8. DAILY MAINTENANCE & LUBRICATION Check all hardware daily before operation. Tighten hardware to torque values as specified in the Torque Chart, page 67 unless otherwise specified. IMPORTANT NOTE: To prevent mounting kit hardware from loosening during operation always torque mounting kit hardware to specified torque noted in Loader Operator Manual With the engine off and the bucket on the ground, inspect all hoses for cuts or wear. Check for signs of leaks and make sure all fittings are tight. CAUTION: Escaping hydraulic fluid under pressure can have sufficient force to penetrate skin, causing serious personal injury. Before disconnecting lines, be sure to relieve all pressure. Before applying pressure to system, be sure all connections are tight and that lines, tubes, and hoses are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately. (1) Hydraulic line. (2) Cardboard. (3) Magnifying glass. Service your loader at the intervals and locations as specified. When you service your loader, use only high quality lubricants. The engine hour meter on the tractor shows the amount of hours the engine has worked. Use the hour meter to service your loader at the correct time periods. CAUTION: When servicing the loader or leaving operator's seat for any reason, always: Lower the loader to ground. Turn on Comfort Drive, if equipped Apply the parking brake securely Shut off the engine Turn on tractor switch so Comfort Drive Solenoid is energized. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions. Return lever or levers to neutral position. Turn off tractor switch and remove the key. Check the tractor hydraulic fluid level as specified in the tractor Operator Manual. NOTE: When checking hydraulic system fluid level, the loader boom must be on the ground with the bucket or attachment resting flat on a level surface. 25

26 8.2. LOADER LUBRICATION Position bucket and/or attachment level with ground, lower loader boom to ground, and relieve all hydraulic pressure before lubricating There are 12 grease fittings one at each pivot point. Lubricate pivots as specified. (1) Lubricate these 12 pivot points every 5 hours of operation CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of a control lever/levers or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury (2) After every 10 hours of loader operation, check that all pin boss hardware, washers, and nuts are secure Flatwasher 3/8" Hardened, 4 places. Acorn Lock Nut 3/8"-16NC, 4 places. Carriage Bolt 3/8"-16NC x 1" Grade 5, 4 places, (not shown) 26

27 To keep mounting kit hardware from loosening during operation, periodically check that all loader mounting kit hardware is torqued to specification noted in Torque Chart, page 67. (1) Check all mounting kit hardware torque. (Refer to mounting kit instructions for exact quantity and placement of hardware.) 2 1. Torque all loader mounting bolts during initial installation of loader per Operators Manual. 2. The owner/operator is responsible for checking and retorquing all loader mounting hardware after he/she operates loader 3 to 5 hours. 3. Inspect bolt torque every 25 hours of loader operation, if loose retighten. 4. Failure to follow these instructions may cause tractor or loader damage During initial setup and as required apply a small amount of grease to each loader bracket in area of top receiver and guide. This will aid in parking loader. (2) To aid in mounting and dismounting loader, apply small amount of grease to these areas Before servicing your tractor, always do one of the following. CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of a control lever/levers or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury. (1) Park the loader off of the tractor. (2) Position loader bucket against dump stops, then lower to ground and relieve all hydraulic pressure. 27

28 8.3. LOADER EQUIPPED WITH OPTIONAL GRILL GUARD To service tractor, it may be necessary to remove grill guard crosstube assemblies by loosening hardware and sliding crosstube assemblies out from between grill guard uprights. 1st Loosen Crosstube Assembly Hardware 2nd Remove Crosstube Assemblies from between Grill Guard Uprights See your grill guard installation instructions for details of your grill guard To prevent attachment cylinder damage, always keep top of front loader arms and area between attaching plates free of all debris such as rocks or material that can become hard when dried or frozen. (1) Keep This Area Clean Top of front loader arms. (2) Keep This Area Clean Between attaching plates. (1) Keep Clean (2) Keep Clean 28

29 8.4. SKID STEER QUICK ATTACH LUBRICATION IMPORTANT: To maintain your Skid Steer Tool Carrier System functioning properly, always keep handle components and latching areas clean. Keep all these areas clean Keep these areas clean on your attachment Inspect latching components and pins. If damaged, only replace with Factory approved components. Check and tighten this 1/2" bolt after every 20 hours of operation, 1 place each side Lubricate these 2 grease fittings, 2 places each side, every 2 months of operation Grease skid steer tool carrier as follows: 1. Park bucket or attachment. 2. Grease 2 grease zerks each side as shown. IMPORTANT: To maintain your Skid Steer Tool Carrier System functioning properly, always inspect Skid Steer Tool Carrier System components for damage or wear. If damage or wear exists, replace components immediately. 29

30 9. OPERATING INSTRUCTIONS The loader should be operated with the tractor engine running from 1700 to 2200 rpm. Excessive speeds are dangerous, and may cause bucket spillage and unnecessary strain on the tractor and loader. When operating in temperatures below 30 o F, run the tractor engine below 1200 rpm until the hydraulic fluid temperature exceeds 30 o F. The following text and illustrations offer suggested loader and tractor operating techniques. IMPORTANT: If your loader is equipped with Optional Hydraulic Self Leveling refer to following operating instructions along with operating instructions in Optional Hydraulic Self Leveling section in this manual FILLING THE BUCKET Approach and enter the pile with a level bucket. Then rollback and lift the bucket. The rollback and lifting of the bucket will increase efficiency because a level bucket throughout the lifting cycle resists bucket lift and increases breakaway effort. NOTE: Do not be concerned if the bucket is not completely filled during each pass. Maximum productivity is determined by the amount of material loaded in a given period of time. Time is lost if two or more attempts are made to fill the bucket on each pass. LIFTING THE LOAD When lifting the load, keep the bucket positioned to avoid spillage. CAUTION: Do not attempt to lift bucket or attachment loads in excess of the loader capacity CARRYING THE LOAD Position the loader in a low position when transporting a loaded or empty bucket or attachment. Use extreme care when operating the loader on a slope. Keep the bucket as low as possible. This keeps the bucket and tractor center of gravity low and will provide maximum tractor stability. CAUTION: Operating the loader on a hillside is dangerous and is not recommended. When transporting a load, keep the bucket as low as possible to avoid tipping, in case a wheel drops in a rut. 30

31 9.3. DUMPING THE BUCKET Lift the bucket just high enough to clear the side of the vehicle. Move the tractor in as close to the side of the vehicle as possible, then dump the bucket LOWERING THE BUCKET After the bucket is dumped, back away from the vehicle while lowering and rolling back the bucket OPERATING WITH FLOAT CONTROL During operation on hard surface, keep the bucket level and position the lift control in the float position to permit the bucket to float on the work surface.if hydraulic down pressure is exerted on the bucket, the cutting edge will wear faster than normal. The float position will also avoid mixing of surface material with stockpile material. The float position will reduce the chance of surface gouging while removing snow or other material, or when working with a blade LOADING FROM A BANK Choose a forward gear that provides a safe ground speed and power for loading. CAUTION: Exercise caution when undercutting high banks. Dirt slides can be dangerous. Load from as low as possible for maximum efficiency. Loader lift and breakaway capacity diminish as loading height is increased. Side cutting is a good technique for cutting down a big pile. If the pile sides are too high and liable to cause cave-in, use the loader to break down the sides until a slot can be cut over the top. Another method for large dirt piles is to build a ramp approach to the pile. It is important to keep the bucket level when approaching a bank or pile. This will help avoid gouging the work area. 31

32 9.7. PEELING AND SCRAPING Use a slight bucket down angle, travel forward, and hold the lift control forward to start the cut. Make a short cut and breakout cleanly. With the bucket level, start a cut at the notch approximately 2 in. deep. Hold the depth by feathering the tilt control to adjust the cutting edge up or down. When the front tires enter the notch, adjust the lift cylinder to maintain proper depth. Make additional passes until the desired depth is reached. During each pass, use only the tilt control while at working depth. This will allow you to concentrate on controlling the bucket angle to maintain a precise cut LOADING LOW TRUCKS OR SPREADERS FROM A PILE For faster loading, minimize the angle of turn and length of run between pile and spreader. Back grade occasionally with a loaded bucket to keep the work surface free of ruts and holes. Also, hold the lift control forward so the full weight of the bucket is scraping the ground. Use the heel of the bucket BACKFILLING Approach the pile with the bucket flat. Poor operating methods actually move no more dirt and make it more difficult to hold a level grade. Do not use the bucket in the dumped position for bulldozing. This method will impose severe shock loading on the dumplinkage, the tilt cylinders, and the tractor. Leave dirt in the bucket because dumping on each pass wastes time. Operate at right angles to the ditch, taking as big a bite as the tractor can handle. 32

33 Leave dirt that drifts over the side of the bucket for final clean up. Pile dirt on the high side for easier backfilling on a slope HANDLING LARGE HEAVY OBJECTS CAUTION: Handling large heavy objects can be extremely dangerous due to: Danger of rolling the tractor over. Danger of upending the tractor. Danger of object rolling or sliding down the loader boom onto the operator. CAUTION: If you must perform the above work, protect yourself by: Never lifting the load higher than necessary to clear the ground when moving. Adding rear ballast to the tractor to compensate for the load. Never lifting large objects with equipment that does not have an anti-rollback device. Moving slowly and carefully; avoiding rough terrain BACK GRADING When back grading, the angle between the bottom of the bucket and the ground must not be more than 15 degrees. Failure to follow these instructions could cause loader tilt cylinders to fail and void warranty. 15 Never use bucket or other attachment in position shown to push or doze material. This will cause excessive pressure in bucket cylinder and will cause failure to your loader, which is not covered under warranty. NOTE: Never dump bucket over with grapple open and use grapple as a ripper. This will cause excessive pressure in bucket cylinder and will cause failure to your loader, which is not covered under warranty. 30 Completely Back Never push on bucket when it is in this position. 33

34 9.12. PROHIBITED OPERATIONS Step 3: Apply force with bucket cylinders Never perform following operation with a loader. Failure to follow these instructions could cause high pressure spikes in system causing failure or damage to cylinders, hoses or loader frame members. Step 1: Extend lift cylinder Step 2: Hook bucket edge to solid object Step 3: Apply force with bucket cylinders Step 2: Hook bucket edge to solid object Step 1: Extend lift cylinders CAUTION: Doing this type of operation with your tractor and loader could result in personal injury or death. Step 3: Apply force with bucket cylinders Never perform following operation with a loader. Failure to follow these instructions could cause high pressure spikes in system causing failure or damage to cylinders, hoses or loader frame members. Step 1: Extend lift cylinder Step 2: Connect chain or nylon strap to bucket and solid object Step 3: Apply force with bucket cylinders Step 4: Drive tractor forward or rearward Step 4: Drive tractor forward or rearward Step 2: Connect chain or nylon strap to bucket and solid object Step 1: Extend lift cylinders CAUTION: Doing these types of loader operations with your tractor and loader could result in personal injury or death. Damage caused to any of these components due to these types of loader operations are not covered under warranty. 34

35 10. DISMOUNTING THE LOADER CAUTION: Always park loader with material bucket attached to the loader. CAUTION: When servicing the loader or leaving operator's seat for any reason, always: Lower the loader to ground. Turn on Comfort Drive, if equipped Apply the parking brake securely Shut off the engine Turn on tractor switch so Comfort Drive Solenoid is energized. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions. Return lever or levers to neutral position. Turn off tractor switch and remove the key. CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury. CAUTION: Do not allow bystanders in loader work area. IMPORTANT: Never allow weight of tractor to be placed on parking stands when mounting or dismounting loader Position the loader on a hard level surface. The more level the surface the easier the loader is to mount and dismount Raise loader, dump bucket 90 o to ground, and then lower loader so that bucket cutting edge is approximately 1/2" off of ground. Bearing Box Tower Cutting edge of bucket 1/2" off of ground Remove snap pins from handle pins located in bearing boxes. Bearing Box Handle Pin Snap Pin 35

36 Remove parking stands from storage positions in the boom crosstubes. Return hairpin cotters to storage positions. Parking Stand in Storage Position Hairpin Cotter in Storage Position Position parking stands in attaching brackets on inside of each boom arm. Secure using clevis pins and hairpin cotters. Clevis Pin and Hairpin Cotter in Park Position. Attaching Bracket. Parking Stand in Park Position Make sure long end of parking stand is located toward rear end of tractor. Photo shows parking stands in park position and loader ready to be dismounted. Parking Stands in Park Position with long end of stands positioned rearward 36

37 If your loader is equipped with Comfort Drive, Lower the loader to ground. Turn on Comfort Drive, if equipped Apply the parking brake securely Shut off the engine Turn on tractor switch so Comfort Drive Solenoid is energized. Release all hydraulic pressure in all circuits by moving hydraulic control lever or levers in all positions. Return lever or levers to neutral position. Turn off tractor switch and remove the key. then disconnect Comfort Drive electrical disconnect located on RH side of tractor in area of Mid Mount Coupler Kit or Mid Mount Faster Coupler Kit Retract tilt cylinders (A) to roll bucket back and retract lift cylinders (B) to lower loader boom down until parking stands make firm contact with ground. NOTE: Driving the tractor forward slowly while positioning loader will allow parking stands to contact ground firmly. A B Bucket resting on ground. Parking Stands contacting ground firmly Retract lift cylinders (C) until bearing box pins (D) rotates out of bracket towers. C D 37

38 Slowly drive tractor forward while (E) retracting tilt cylinders (F). Doing this will allow bearing boxes to guide loader as it is being parked off of tractor. This will allow loader to be held in position to clear exhaust and tractor hood during dismounting. F Bearing Boxes E Retract tilt cylinders (G) completely Make sure all loader components clear tractor. Back tractor away (H) slightly Stop the tractor engine and then work valve handle/handles to relieve hydraulic fluid pressure in lines. Refer to tractor operator manual for additional information. G H Reinstall handle pins and snap pins to bearing boxes for storage Disconnect loader hoses. Start tractor and slowly back tractor away from the loader. IMPORTANT: To avoid hydraulic hose damage, be alert and make sure hoses do not catch on tractor and/or loader during mounting or dismounting. WARNING: Make sure parked loader is on a hard level surface. Engage all safety devices to prevent loader from falling and being damaged or injuring someone. Do not repair loader if it is not mounted on the tractor. Loss of hydraulic fluid or removal of parts could cause loader to collapse resulting in injury. 38

39 11. MOUNTING THE LOADER CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury. CAUTION: Do not allow bystanders in loader work area. IMPORTANT: Never allow weight of tractor to be placed on parking stands when mounting or dismounting loader. B To aid in mounting and dismounting loader, apply a small amount of grease, if needed, to each tower in areas of tower bottom receiver (A), tower top receiver (B), and handle pin bushing (C). Tower A C Slowly drive tractor forward to a position where the loader hoses can be connected to the tractor. NOTE: Always clean both Male and Female Quick Couplers before connecting them. Failure to clean couplers can cause coupler O-ring damage and oil leakage Stop the engine. Connect the loader hydraulic hoses Remove handle pins and snap pins from bearing boxes. IMPORTANT: When driving tractor into parked loader, take care not to drive tractor too far forward causing Comfort Drive Accumulator or boom cross tube to contact any tractor components. Failure to follow these instructions could cause damage to loader, which is not covered under warranty. 39

40 Check that lift cylinders are fully retracted. Position loader to clear tractor muffler and hood. Then drive tractor forward. Use tilt cylinders to position height of bearing box top pin making sure all loader components clear all tractor components. Bearing Box Top Pin Tower Top Receiver Bearing Box Tower Align bearing box top pin with tower top receiver guide post, both sides. Make sure loader is centered right to left on both towers. Extend tilt cylinders further until top bearing box pin seats in both towers. Tower Bearing Box Bottom Pin Bearing Box Centered Right to Left on Tower Bearing Box Top Pin Tower Top Receiver Guide Post Tower Top Receiver Bearing Box Extend lift cylinders (A) slowly making sure loader seats completely in tower top receivers (B) and tower bottom receivers (C). D B A C 40

41 Raise loader, position bucket 90 o to ground then lower until cutting edge is 1/2" off of ground Secure loader to mounting brackets as follows Reinstall handle pins to bearing boxes and secure using snap pins. Bearing Box Handle Pin Snap Pin Position parking stands in attaching brackets on inside of each boom arm. Secure using clevis pins and hairpin cotters. Clevis Pin and Hairpin Cotter in Park Position. Attaching Bracket. Parking Stand in Park Position Return parking stands to storage positions in the boom crosstubes. Secure using hairpin cotters. Parking Stand in Storage Position. Hairpin Cotter in Storage Position Lower loader to ground then route and secure loader hydraulic hoses If your loader is equipped with Comfort Drive reconnect electrical disconnect. Make sure it is routed so it will not be damaged during loader operation. IMPORTANT: To avoid hydraulic hose damage, be alert and make sure hoses do not catch on tractor and/or loader during mounting or dismounting. 41

42 12. SKID STEER TOOL CARRIER SYSTEM IMPORTANT: Read safety information in this section and on decal before operating attachment. NOTE: Skid Steer Tool Carrier System is standard equipment WARNING: Always read and follow operating instructions before operating Skid Steer Tool Carrier System RECOMMENDED LOADER FACTORY APPROVED ATTACHMENTS Use only Loader Factory Approved Attachments for mounting on this Skid Steer Tool Carrier System: KMW 72, 78 or 84 Bucket, Bale Spear and Pallet Fork NON-LOADER FACTORY ATTACHMENTS If you are going to connect a non-loader Factory Attachment to this Skid Steer Tool Carrier System, read and understand the following instructions and safety information. Always make sure Skid Steer Tool Carrier is locked onto all attachments. NOTE "A": If your attachment back is not running at a 20 degree angle, your loader rollback and dump angles will change per attachment angle change. NOTE "B": If your attachment point is lower than this, your attachment may not touch the ground when loader is fully lowered. IMPORTANT: Failure to follow above instructions could cause damage to loader components from contact with attachment which are not covered under warranty. 42

43 12.3. SKID STEER TOOL CARRIER SYSTEM SERVICE & LUBRICATION IMPORTANT: To maintain your Skid Steer Tool Carrier System functioning properly, always keep handle components and latching areas clean. Keep all these areas clean Keep these areas clean on your attachment Inspect latching components and pins. If damaged, only replace with Factory approved components. Check and tighten this 1/2" bolt after every 20 hours of operation, 1 place each side Lubricate these 2 grease fittings, 2 places each side, every 2 months of operation Grease skid steer tool carrier as follows: 3. Park bucket or attachment. 4. Grease 2 grease zerks each side as shown. IMPORTANT: To maintain your Skid Steer Tool Carrier System functioning properly, always inspect Skid Steer Tool Carrier System components for damage or wear. If damage or wear exists, replace components immediately. 43

44 13. INSTALLATION & OPERATION OF SKID STEER TOOL CARRIER SYSTEM IMPORTANT: Read safety information in this section and on decal before operating attachment. WARNING: Always read and follow operating instructions before operating Skid Steer Tool Carrier System INSTALLATION INSTRUCTIONS IMPORTANT: Do not extend bucket cylinders without Skid Steer Tool Carrier installed on loader. Failure to follow these instructions could cause loader damage and void warranty Install Skid Steer Tool Carrier to loader. Secure as shown. NOTE: Locate tilt cylinder grease zerk downward. Pivot Pin 1" x 4.44" secured with Carriage Bolt 3/8" x 1", Hardened Flatwasher and Acorn Lock Nut, 2 places each side SKID STEER TOOL CARRIER HANDLES IN DISENGAGED POSITION To position handles into the handle disengaged position, pull skid steer tool carrier handle upward. Pull Handles Upward SKID STEER TOOL CARRIER HANDLES IN ENGAGED POSITION To position handles into the handle engaged position, push skid steer tool carrier handle downward until they latch into position. NOTE: Handles should be positioned parallel to ground if properly latched. Push Handles Downward. 44

45 14. INSTALLING BUCKET OR ATTACHMENT TO SKID STEER TOOL CARRIER IMPORTANT: Refer to Page 44 for instructions concerning Skid Steer Tool Carrier Handles Disengaged and Engaged Positions. CAUTION: Before leaving the tractor seat, stop the engine and lock brakes when installing or removing bucket or attachment. CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury OPERATING INSTRUCTIONS To attach bucket or attachment to loader, lower loader boom to ground with Skid Steer Tool Carrier attachment rolled forward slightly To position handles into the handle disengaged position, pull skid steer tool carrier handle upward. Pull Handles Upward Roll Skid Steer Tool Carrier attachment forward by extending tilt cylinders just enough to allow Skid Steer Tool Carrier upper vee to engage Skid Steer attachment vee channel. Drive tractor forward, aligning Skid Steer Tool Carrier vee components. Align Skid Steer Tool Carrier vee with Skid Steer Attachment vee channel. NOTE: Over extension of tilt cylinders during this operation could cause damage to Skid Steer Tool Carrier handles due to handles contacting bucket or attachment. 45

46 From tractor seat operator will not be able to see top vee channel during final engagement of component. However before driving completely in operator can follow instruction then align right to left by aligning tool carrier surface with bucket surface as specified in photo. From tractor seat align these two edges after following step When Skid Steer Tool Carrier attachment is aligned with bucket or attachment, raise loader boom slowly making sure Skid Steer Tool Carrier vee components engage. Then roll Skid Steer bucket or attachment back slowly Position loader so attachment is approximately 1" off ground To position handles into the handle engaged position, push skid steer tool carrier handle downward until they latch into position. NOTE: Handles should be positioned parallel to ground if properly latched. Push Handles Downward. 46

47 Check that bucket or attachment is securely attached to Skid Steer Tool Carrier by raising loader boom 3 to 4 feet, dumping bucket or attachment against stops, and checking to be sure bottom of bucket or attachment does not roll forward away from Skid Steer Tool Carrier Assembly Inspect Skid Steer Tool Carrier attaching areas to verify that Skid Steer Tool Carrier pins have engaged bucket or attachment fully. Bucket or Attachment support bar. Skid Steer Tool Carrier Pin Assembly engaging bucket or attachment. IMPORTANT: If properly latched into Skid Steer Tool Carrier attachment, the lower groove pin should be contacting pin support bar. Bucket or Attachment support bar. Bucket or Attachment contact point. Skid Steer Tool Carrier Pin Assembly engaging bucket or attachment. WARNING: A bucket or attachment that is not securely locked into Skid Steer Tool Carrier could come off during loader operation causing serious injury or death. 47

48 15. REMOVING BUCKET OR ATTACHMENT FROM SKID STEER TOOL CARRIER IMPORTANT: Refer to Page 44 for instructions concerning Skid Steer Tool Carrier Handles Disengaged and Engaged Positions. CAUTION: Before leaving the tractor seat, stop the engine and lock brakes when installing or removing bucket or attachment. CAUTION: Do not stand, walk, or work under a raised loader or attachment unless it is securely blocked or held in position. Accidental movement of valve handle/handles or leaks in the hydraulic system could cause the loader to drop, or attachment to dump, causing severe injury OPERATING INSTRUCTIONS To disconnect bucket or attachment from loader, position bucket or attachment slightly rolled back and approximately 1" off of ground Position handles into the handle disengaged position by pulling skid steer tool carrier handle upward. Pull Handles Upward Roll bucket or attachment forward and lower to ground. Back loader away from bucket or attachment. NOTE: Over extension of tilt cylinders during this operation could cause damage to Skid Steer Tool Carrier handle due to handle contacting bucket or attachment. 48

49 16. SKID STEER BUCKET IMPORTANT: Read safety information in this section and on decals before operating attachments. WARNING: To avoid serious injury or death from large round or square hay bale handling: Use only Factory bale spear or bale retaining device handler attachment when handling round bales. Do not handle large square bales without a retaining device handler attachment Do not use buckets, forks, or other attachments without bale retaining devices. Do not use loader for handling large, heavy objects such as logs, tanks, etc. WARNING: To avoid serious injury or death, realize handling large heavy objects can be extremely dangerous due to: Danger of rolling the tractor over. Danger of upending the tractor. Danger of the object rolling or sliding down the loader arms onto the operator. WARNING: To avoid serious injury or death: Do not lift or carry anyone on buckets, forks, probes, or any other portion of the loader or loader attachments. Avoid contact with electrical power lines by loader or attachment WARNING: Inadvertent movement of the loader or attachment could result in serious injury or death SKID STEER BUCKET INSTALLATION INSTRUCTIONS TO SKID STEER TOOL CARRIER IMPORTANT: Refer to Pages 45 to 47 for instructions concerning Installing Attachment to Skid Steer Tool Carrier. IMPORTANT: Refer to Page 48 for instructions concerning Removing Attachment from Skid Steer Tool Carrier. 49

50 17. SKID STEER BALE SPEAR IMPORTANT: Read safety information in this section and on decals before operating attachments. IMPORTANT: Never park loader with Bale Spear attached to loader. Always dismount loader with bucket installed on loader. CAUTION: When transporting a round bale, tilt the bale spear slightly back from level and carry the load in a low position. CAUTION: Never raise round bale to full height with bale spear rolled back as serious injury or death could occur. CAUTION: To prevent bodily injury, park and store bale spear with points pointed against bale, building, or other stable object. 50

51 17.1. SKID STEER BALE PROBE IMPORTANT: This spear is a high strength alloy drop forged steel and should not be welded or heattreated. IMPORTANT: Maximum load limit on super penetrator bale spear is 2,000 pounds ASSEMBLY INSTRUCTIONS Install Bale Spear into tapered sleeve and secure with nut. Torque nut 515 ft. lb. Failure to follow these instructions could cause damage to spear and void your warranty. (1) Upper Spear. Flat surface of spear located upward. (2) Tapered Sleeve. (3) Upper Spear Nut, 28mm. Torque nut to 515 ft. lb. (3) (2) (1) INSTALLATION INSTRUCTIONS TO SKID STEER QUICK ATTACH IMPORTANT: Refer to Pages 45 to 47 for instructions concerning Installing Attachment to Skid Steer Quick Attach. IMPORTANT: Refer to Page 48 for instructions concerning Removing Attachment from Skid Steer Quick Attach OPERATING INSTRUCTIONS With bale spear level with ground, slowly spear bale slightly above center With all three spears completely engaged into bale, tilt bale spear slightly back from level and transport the load in a low position. Spear bale slightly above center of bale. 51

52 18. SKID STEER PALLET FORK IMPORTANT: Read safety information in this section and on decals before operating attachments. WARNING: The pallet fork attachment is specifically designed to engage and load palleted materials. Do not use forks to handle large loads such as bales, posts, etc. as they can fall or roll back onto operator causing serious injury or death. 52

53 18.1. SKID STEER PALLET FORK The Skid Steer Pallet Fork has two tines each 1-1/4" x 4" x 42" ASSEMBLY INSTRUCTIONS Install (4) guard to (7) pallet fork frame using (5) 1-2" x 1-1/2" bolt, lockwasher, flatwasher, and nut, 2 places each side Install (3) forks to (7) pallet fork frame using (1) pins, 2 places secure using (2) 3/8" x 2-1/2" bolts, lockwashers, and nuts, 4 places Locate (6) hooks on (3) forks on backside of angle to prevent fork rotation. Refer to Pallet Fork illustration in service parts pages for additional assembly instructions INSTALLATION INSTRUCTIONS TO SKID STEER QUICK ATTACH IMPORTANT: Refer to Pages 45 to 47 for instructions concerning Installing Attachment to Skid Steer Quick Attach. IMPORTANT: Refer to Page 48 for instructions concerning Removing Attachment from Skid Steer Quick Attach OPERATING INSTRUCTIONS The operator must keep the load centered and as far back on the forks as possible. Operator must always keep load level. Carry the load low and at a slow speed PARKING INSTRUCTIONS Never park loader with Pallet Fork attached to loader. Always dismount loader with bucket attached to loader. 53

54 19. OPTIONAL ORIFICE KIT FOR USE WITH HYDRAULIC KITS UTILIZING TRACTOR SUPPLIED VALVE Install orifice fitting into loader tilt cylinder rod end (identified with Red Tie) if not previously installed at Factory. (1) Orifice Fitting 10 Fitting Straight Special 11 (1220/1220 HL Loader) Orifice 0.111" 12 Fitting Straight JICF 3/4" x ORBM 3/4" 13 Fitting Assembly 14 Connect this end to loader hose from loader Frame. 15 Orifice Oil Flow Direction. 16 Free Flow Oil Direction IMPORTANT: When installing orifice fitting in system, the free flow oil direction is towards loader and orificed oil flow is towards valve or tractor remote. When orifice fitting is installed in system correctly, cavitation of attachment cylinder will be reduced thus reducing free movement of bucket or attachment, which could be caused by cylinder cavitation. NOTE: When equipping loader with Hydraulic Self Leveling this orifice fitting will need to be moved to the location specified in Hydraulic Self Level Installation Instructions. 54

55 20. OPTIONAL ORIFICE KIT FOR USE WITH HYDRAULIC KITS UTILIZING KMW SUPPLIED VALVE Optional Orifice Installation: Purchase orifice plate through loader service parts. Remove female quick coupler from port B2.Install orifice fitting by dropping it into port "B2" with slot of orifice facing upward. Reassemble female quick coupler into Port "B2" to secure orifice into port. Port "B2" in Loader Valve. Orifice (slot outward). Female Quick Coupler. Port "B2" in Loader Valve. NOTE: Optional orifice is used to reduce bucket cylinder cavitation during regular dump operation. If your operation requires a different orifice size, order blank orifice through service parts (See parts pages for part number). Blank orifice can be drilled to your loader application. Smaller hole will reduce cavitation at low RPM but it will decrease dump speed. Larger hole will increase cavitation at low RPM but it will increase dump speed. Use of regen during dumping operation will eliminate any bucket cylinder cavitation and eliminate orifice use. See valve operation instructions in this manual for further loader valve operation instructions. 55

56 21. LEAK DOWN INSPECTION IMPORTANT NOTE: Following leakage test should only be done by a qualified mechanic FRONT END LOADER FIELD LEAK DOWN INSPECTION AND TEST CAUTION: Do not stand, walk, or work under a raised loader tilt or attachment unless it is securely blocked and held in position. CAUTION: Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Do not use HANDS to search for suspected leaks. If injured by escaping fluid, obtain medical treatment immediately. CAUTION: Visually check for hydraulic leaks and broken, missing, or malfunctioning parts. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. Escaping hydraulic fluid or diesel fuel leaking under pressure can have sufficient force to penetrate the skin and cause serious infection or other personal injury. If injured by leaking fluid, seek medical attention immediately. CAUTION: To prevent personal injury, relieve all pressure before disconnecting fluid lines. CAUTION: Before applying hydraulic pressure, make sure all hydraulic connections are tight and components are in good condition. CAUTION: Be sure to purge all the air from the hydraulic system before attempting to raise or lower this machine Make sure all fittings are tight and not leaking. Make sure that there is no external leakage from the valve, fittings or cylinders. If leakage exist repair before doing any of the following test Make sure that there is adequate hydraulic fluid in the reservoir Install pressure gauge in the circuit you are testing. If testing Lift cylinder leak down install pressure gauge in base and rod end circuit of lift cylinder between the loader valve and the lift cylinder. If testing the tilt cylinder leak down install pressure gauge in rod end circuit of the tilt cylinder between the loader valve and the cylinder Photo shows typical pressure gauge setup. Connect 5000 psi min. pressure gauge between loader valve and cylinder circuit you are checking Either quick couple or solid mount the pressure gauge in the circuit you are testing. Make sure there are no hydraulic line leaks in system before testing your loader Cycle or operate the hydraulic system till the control valve is warm to the touch. 56

57 IMPORTANT: Always check leakage of lift cylinder seals before you test lift circuit loader valve spool leakage LEAKAGE TEST FOR LIFT CYLINDER SEALS (Open Center Systems) NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch Install pressure gauges in the lift cylinder rod and base end circuit. Install pressure gauge in the base and rod end of Lift cylinder With no load in bucket raise loader to full height and then hold pressure on unit for a few seconds. Read Base end pressure it should equal tractor hydraulic system pressure. Leave unit raised for a 5 to 10 minutes and then read rod end pressure. Rod end pressure should read zero. If pressure starts to increase in rod end and or base end of cylinder. Lower loader and repair or replace damaged lift cylinder. If rod end pressure does not increase no cylinder repair is required. This test can also be done with some load in bucket and with the loader only raised slightly off of ground. This will increase the pressure in the cylinder and check the seals at a higher pressure. NOTE: Make sure that the pressure in the rod end circuit is zero or very low when starting this test. OPTIONAL WAY TO CHECK LIFT CYLINDER SEAL LEAKAGE ON OPEN CENTER SYSTEMS. (FOLLOW THESE INSTRUCTIONS IF CHECKING A CLOSED CENTER OR LOAD SENSE SYSTEM) Remove lift cylinder rod end hose. Install tee fitting with a high pressure ball valve and drain hose assembled to the rod end of the lift cylinder circuit. Insert end of drain hose into a drain pan. Tee Fitting. High Pressure Ball Valve. Drain Hose. Lift Cylinder Rod End Hose. 57

58 High Pressure Ball Valve and fittings installed on a loader. Lift Cylinder Rod End Hose. Tee Fitting. High Pressure Ball Valve. Drain Hose Install a pressure gauge in the lift circuit base end With high pressure ball valve in off position, place a load in the bucket and raise loader to some height. The load in the bucket and the lift height should be such that it induces a target reference pressure of 1500 psi in the cylinders Disconnect rod end lift cylinder circuit from loader valve by disconnecting quick coupler. If quick coupler does not exist install one in line before proceeding with this test Slowly open high pressure ball valve directing drain hose to drain pan. Note: If oil flows out of drain hose and loader lowers, cylinders will need to be repaired or replaced. Note: If no flow is seen, no repair of lift cylinder is required Reconnect rod end of lift cylinder circuit by reconnecting quick coupler. Base end Of lift cylinder Lower loader to ground. Relieve pressure and remove high pressure ball valve and tee fitting. Re-connect loader hose and fitting. Rod end of lift cylinder. 58

59 IMPORTANT: Always check leakage of lift cylinder seals before you test lift circuit loader valve spool leakage LEAKAGE TEST FOR LIFT CIRCUIT LOADER VALVE SPOOL NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch Install a pressure gauge in the lift circuit base end Cycle the lift cylinders to full extend and then full retract a minimum of 5 times to expel any air in the system. The cylinders should be cycled with the engine near maximum rpm. The bucket should not be loaded during cycling Place a load in the bucket and raise to some height. The load in the bucket and the lift height should be such that it induces a target pressure of 1000 psi in the lift cylinder base end circuit Disconnect rod end lift cylinder circuit from loader valve by disconnecting quick coupler. If quick coupler does not exist install one in line before proceeding with this test Use a permanent marker and mark a line on the cylinder rod 3 inches away from the tube end of the cylinder. (See photo on following page) After a 10 minute period of time measure the distance between the line and the end of the cylinder and subtract the distance from 3 inches to determine how much the cylinder has retracted Refer to Leak down Rate chart in these instructions for the acceptable leak down rate for your specific cylinder sizes. Step A: Mark cylinder rod with a permanent marker 3 from cylinder end. Step B: Then measure the distance between end of cylinder and mark after a 10 minute period of time. Rod End of Lift Cylinder Initial Mark on Lift Cylinder Rod 3 from end of cylinder LEAKAGE TEST FOR TILT OR BUCKET CYLINDER, SEALS NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch Install a pressure gauge in the tilt circuit rod end Cycle the tilt cylinders to full extend and then full retract a minimum of 5 times to expel any air in the system. The cylinders should be cycled with the engine near maximum rpm. The bucket should not be loaded during cycling. Use regen function of valve (If equipped) when expelling air from the tilt circuit Lower the loader to the ground, relieve hydraulic pressure and disconnect rod end tilt cylinder circuit from loader valve by disconnecting quick coupler. If quick coupler does not exist install one in line before proceeding with this test. 59

60 Place a load in the bucket and raise the boom slightly off the ground. The load should be such that it induces a target reference pressure between 1000 to 1500 psi in the cylinders refer to pressure gauge previously installed Place a mark using a permanent marker on the cylinder rod at the end of the cylinder. NOTE: Never mark the cylinder until the weight has been applied to the loader and your pressure gauge reads 1000 to 1500 psi. Measure from end of cylinder after 10 minutes. Initial Mark on Tilt Cylinder Rod After a 10 minute period of time measure the distance from the end of cylinder to the mark If this distance has increased then some internal leakage is present. If excessive leakage is found cylinder will need to be replaced or repaired Lower the loader and bucket to the ground, and re-connect the rod end hose TILT OR BUCKET CYLINDER VALVE SPOOL LEAKAGE NOTE: Clean all parts thoroughly before disassembling any fittings. Cycle or operate the hydraulic system till the control valve is warm to the touch Install a pressure gauge in the tilt circuit rod end Cycle the tilt cylinders to full extend and then full retract a minimum of 5 times to expel any air in the system. The cylinders should be cycled with the engine near maximum rpm. The bucket should not be loaded during cycling. Use regen function of valve (if your loader is equipped with it) when expelling air from the tilt circuit With the bucket lip approximately level and on the ground, place a load in the bucket and raise the boom slightly off the ground. The load should be such that it induces a pressure of 1000 psi in the cylinder rod end. Refer to pressure gauge previously installed. Place a mark using permanent marker on the cylinder rod at the end of the cylinder after load has been applied. (Refer to previous page photo.) After a 10 minute period of time measure the distance from the cylinder end to the mark to determine how much the cylinder has extended. Then refer to Leak down Rate Chart in these instructions for the acceptable leak down rate for your specific cylinder sizes If valve leak down rate is found to be more than allowable rate contact factory before returning valve. IMPORTANT: These tests must be done very accurately to make sure the results are accurate. Any valve that is returned and not found to exceed the manufacture's allowable leakage rate will not be covered under warranty. IMPORTANT: Contamination in hydraulic system will cause damage to the loader valve which will increase valve spool leakage rates. If a returned valve is found to be damaged because of contamination it will not be covered under warranty. Keep your hydraulic system maintained at all times and make sure you clean all fittings and etc. when disconnecting or connecting hydraulic fittings. 60

61 21.6. ACCEPTABLE LIFT CYLINDER LEAK DOWN RATES IMPORTANT: Always double check your cylinder size to make sure it matches the information below Following are the allowable leak down rates specific to your loader lift cylinder sizes. If your loader is equipped with a load sense system acceptable leakage rates can be 30% higher than shown in this chart. Lift Cylinder Bore Size Lift Cylinder Outside Diameter Leak Down Rate per 10 minutes Loader Model Numbers 1-1/2" 1-7/8" 1.72 ML /4" 2-1/8" 1.27 ML25, ML104, ML105, ML106, ML108, ML108H 2 2-3/8.97 ML110, ML111, ML112, ML114, ML /4 2-5/8.76 KL1470, KL1470S 2-1/2 2-7/8.62 ML130, ML230, ML260, KL1590, KL1590S, /4 3-1/8.51 ML245, ML255, ML272, ML274, ML278, ML280, 1220/1220 HL 3 3-3/8.43 ML170, ML264, ML265, ML270, ML275, KL1730, /4 3-5/ /2 3-7/ ,1760, ACCEPTABLE TILT OR BUCKET CYLINDER LEAK DOWN RATES IMPORTANT: Always double check your cylinder size to make sure it matches the information below Following are the allowable leak down rates specific to your tilt cylinder sizes. If your loader is equipped with a load sense system leakage rate can be 30% higher than shown in this chart. Tilt Cylinder Bore Size Tilt Cylinder Outside Diameter Tilt Cylinder Rod Diameter Leak Down Rate per 10 minutes Loader Model Numbers 1-1/2 1-7/ ML /4 2-1/ ML25, ML104, ML105, ML106, ML108, ML108H, ML110, ML /8 1-1/4 1.6 ML112,ML114,ML120, ML230,ML260, KL /4 2-5/8 1-1/ ML245, KL1470S, KL1590, KL1595, /4 2-5/8 1-1/ ML130, 1220/1220 HL 2-1/2 2-7/8 1-1/4.83 ML264, KL1595S, KL /2 2-7/8 1-3/ /2 2-7/8 1-1/2.97 ML170, ML255, ML265, ML270, ML272, ML274, ML275, ML278, ML280, 2-3/4 3-1/8 1-1/ , /8 1-3/ /4 3-5/8 1-3/

62 22. TROUBLE SHOOTING PROCEDURES This Trouble Shooting Chart is provided for reference to possible loader operational problems. Determine the problem that best describes the operational problem being experienced and eliminate the possible causes as listed by following the correction procedures. For further assistance contact your dealer TROUBLE SHOOTING FOR ALL LOADERS PROBLEM POSSIBLE CAUSE CORRECTION Lift and Tilt Cylinders inoperative Low hydraulic fluid level. Check and replenish hydraulic fluid. Lift and/or tilt cylinders operate in wrong direction relative to valve handle position Attachment will dump but will not rollback (Only if your loader valve is equipped with regen) Hydraulic hoses connected improperly. Hydraulic Hoses to/from loader valve blocked. Loader valve or tractor main relief valve stuck open. Low system pressure supplied from hydraulic pump. Loader valve linkage broken. Quick disconnect coupler(s) are not fully connected. Hydraulic hose or tubeline blockage. Cylinder piston assembly defective (not sealing). Loader valve blockage. Hydraulic hoses connected incorrectly. Hydraulic circuit connected incorrectly. 62 Check and correct hydraulic hose connections Check for damaged (kinked) hoses, etc. Check system pressure. Repair or replace relief valve. Check system pressure. Repair or replace pump. Inspect. Repair as required. Check coupler connections. Replace coupler(s) if necessary. Check all hoses and tubes for leaks, damage, or restrictions. Replace damaged or restricted hoses or tube lines. Check cylinders for internal leakage as described in service section under cylinder leakage tests. Inspect for blockage. Disassemble valve if necessary. Correct hydraulic hose connections. Refer to plumbing diagram and correct hose connections. Slow or erratic lift Low hydraulic fluid level. Check and replenish hydraulic fluid. Cold hydraulic fluid. Engine R.P.M. too slow (hydraulic pump R.P.M. too slow). Excessive weight in bucket. Material weight exceeds maximum specified loader capacity. Loader valve linkage binding/defective. Aeration of hydraulic fluid Allow hydraulic system to warm up to operating temperature. Increase engine speed to obtain satisfactory loader operation. Reduce material load. Check loader valve linkage and repair if worn/defective. Refer to "Aeration of Hydraulic Fluid".

63 PROBLEM POSSIBLE CAUSE CORRECTION Quick disconnect coupler restriction or coupler. Hydraulic hose or tubeline restriction (hoses/tubeline kinked or pinched). Lift cylinder piston assembly leakage. Relief valve erratic or set below specifications. Loader valve leaking internally. (Bypassing fluid within valve.) Inadequate hydraulic pump capacity. Check coupler connections. Repair or replace. Check hoses and tubelines for evidence of restriction. Check cylinders for leakage. Repair as needed. Check and reset relief valve setting as needed. Replace loader valve and recheck operation. Refer to "Hydraulic Pump Capacity Inadequate". Inadequate lifting capacity Engine R.P.M. too slow. Increase engine R.P.M. Aeration of Hydraulic Fluid (generally indicated by foamy appearance of fluid). Excessive load material weight exceeds specified loader capacity. Relief valve setting below specifications. Lift cylinder piston assembly leakage. Loader valve leaking internally. Hydraulic pump defective. Low hydraulic fluid level. Air leaking into suction side of hydraulic pump. Hydraulic fluid foaming due to improper hydraulic oil usage. Reduce Load. Check and reset relief valve setting as needed. Check cylinders for leakage. Repair as needed. Replace loader valve and recheck operation. Refer to "Hydraulic Pump Capacity Inadequate". Check and refill hydraulic system to proper level. Check for loose or defective connections between reservoir and hydraulic pump. Refer to Tractor Operator s Manual and replace hydraulic oil using recommended hydraulic oil. System relief valve squeals. Cold Hydraulic Fluid. Allow hydraulic fluid to warm up to operating temperature. Loader drops with loader valve spool in "Centered" position (no external oil leakage evident.) Excessive load in bucket. Weight exceeds specified loader capacity. Relief valve setting below specifications. Hydraulic hose, tubeline, or quick disconnect coupler restriction. Cylinder Piston assembly leakage. Loader valve internal leakage. Reduce load. Check and reset valve setting as needed. Check for evidence of restriction in hydraulic oil flow. Repair or replace defective components. Check cylinders for leakage. Replace loader valve and recheck. 63

64 PROBLEM POSSIBLE CAUSE CORRECTION Loader valve spool(s) will not return to centered position. Loader bucket moves freely after dumping load Note: A gradual drop over an extended period of time is a normal condition. Valve handle linkage binding. Loader valve spool centering is broken. Loader valve spool binding in valve body spool bore. Tilt cylinder cavitation has occurred. 64 Run Leakage Test to see if hydraulic components meet specification. Determine origin of binding and repair. Replace centering spring. Disassemble valve for inspection and repair. Use of regen function (if equipped) while dumping load will eliminate problem. Contact Factory for optional orifice sizes. External hydraulic fluid leakage. Loose hydraulic connection. Tighten loose connections. Hydraulic pump capacity inadequate. Lift cylinder rods bend when lift cylinders extended. Bucket cutting edge wear is uneven side to side Bucket cutting edge wear rate is excessive. (Wear rate is even across full width of bucket). Defective hydraulic hose, tubeline, adapter fitting or adapter fitting o- ring. Loader valve o-rings defective. Loader valve spool or body damaged or worn. Cylinder rod packing set leakage. Cold hydraulic fluid. Engine R.P.M. too slow. Low hydraulic fluid supply. Hydraulic hose restriction. Hydraulic pump defective. Excessive shock load on lift cylinders during transport. Bucket is not level to ground. Incorrect operational practices. Excessive down pressure placed on bucket when used on hard abrasive surfaces. Bucket wear pads worn. Note: Extensive use of bucket on concrete or asphalt surfaces will accelerate wear rate of bucket cutting edge. Check for origin of oil leak and replace defective part. Replace defective o-rings. Replace loader valve. Check cylinders for leakage. Repair as needed. Allow hydraulic fluid to warm up to operating temperature. Increase engine R.P.M. Refer to Tractor Operator s Manual for service recommendations. Check for evidence of restriction in hydraulic hoses. Refer to Tractor Operator s manual for recommended service procedures. Replace hydraulic pump if determined to be defective. Replace defective parts. Review and observe proper and safe operational practices. Check rear tire inflation and adjust to level bucket to ground. Refer to operation scraping section for correct operating procedures. Utilize float position. Replace wear pads.

65 PROBLEM POSSIBLE CAUSE CORRECTION Loader is slow and/or will not dump. Loader chatters or vibrates when raising or lowering. Hydraulic oil too heavy. Oil filter plugged. Hydraulic pump worn. Oil line restricted or leaking. Loader valve does not shift properly. Cylinder leaks internally. Faulty valve. Air in hydraulic system. Oil level too low. Change to proper oil. Clean or replace filter. Repair or replace pump. Check all hoses and tubes for leaks, damage, or restrictions. Replace damaged or restricted hoses or tube lines. Inspect clean, repair, or replace valve. Replace seals. Repair or replace valve. Cycle lift cylinders and tilt cylinders. Add oil as required. Slow leakdown. Worn loader valve. Have authorized KMW dealer replace valve. Attachment will dump but will not rollback Worn cylinder piston seals. Hydraulic circuit connected incorrectly. Have authorized KMW dealer replace seals. Check that loader valve is connected to tilt cylinder correctly if valve is equipped with regen funtion TROUBLE SHOOTING OPTIONAL LOADER VALVE If your loader/tractor combination is equipped with an optional KMW Cable Controlled Loader valve and unit reacts in the following manner. PROBLEM POSSIBLE CAUSE CORRECTION Nothing happens when handle switch is activated If you have 12 volts at solenoid valve but valve does not function Tractor switch is not on. Power circuit is not connected. Switch does not have 12 volts. Solenoid valve does not have 12 volts when switch is activated. Spool is sticking. Turn tractor switch on. Connect to tractor power supply that is only activated when tractor switch is on. Trace circuit and find cause. If not, check switch by jumping terminal wires on switch in handle. If 12 volts are at solenoid valve, replace switch Push in on each side of valve spool to free up spool as shown in installation instructions included with your valve kit. Contamination in hydraulic oil causes spool to stick. Replace oil and filter. Solenoid valve section is damaged. Replace solenoid valve section. 65

66 22.3. TROUBLE SHOOTING OPTIONAL COMFORT DRIVE PROBLEM POSSIBLE CAUSE CORRECTION Comfort drive does not activate. Comfort drive does not work properly Turn on comfort drive and check to see if 12 volts are at solenoid. Solenoid not properly grounded Fuse Wire damaged or cut. Switch does not have 12 volts. Tractor switch is not on. Power circuit not connected. Pre-charge pressure is not correct Leak in fluid or gas side of accumulator Circuits not connected correctly If 12 volts are not available, inspect and repair as follows. If not properly grounded, repair. replace if required If damaged repair or replace Trace circuit and find cause. Turn tractor switch on. Connect to tractor power supply that is only activated when tractor switch is on. Check pre-charge pressure of each end of accumulator and correct as required. Repair and replace accumulator seals Trace circuits and make sure large end of accumulator is connected to base end of lift cylinder. 66

67 23. TORQUE CHART 67

68 24. PARTS MANUAL Illustrations All parts are illustrated in "exploded views" which show the individual parts in their normal relationship to each other. Reference numbers are used in the illustrations. These numbers correspond to those in the "Reference Number" column and are followed by the quantity required and description. Directional Reference Right hand (RH) and left hand (LH) sides are determined by standing at the rear of the unit and facing in the direction of forward travel. Parts Order Orders must give the complete description, correct part number, the total amount required, the product model, all the necessary serial numbers, the method of shipment and the shipping address. Parts Breakdown Contact your local KMW dealer for service parts break down. Note: Check loader serial number plate before ordering service parts HL model number is only called out on serial number plate. 68

69 25. DECALS & MANUALS

70 DECALS & MANUALS Reference Description Part No. Qty Decal Warning Decal Warning Decal Danger Decal Warning Decal Warning Decal 1220/1220 HL Decal Important Manual, Operator & Parts Decal Caution Decal SLC

71 DECALS & MANUALS Reference Description Part No. Qty Decal Caution Decal Caution Decal Danger Decal Warning Decal Warning Decal Caution Decal Warning Accumulator

72 26. BOOM ASSEMBLY

73 BOOM ASSEMBLY Reference Description Part No. Qty Bearing Box Assembly (1220) Bearing Box Assembly (1220HL) Boom Assembly (1220) Boom Assembly (1220HL) Parking Leg Pivot Pin 1" x 3.32" Pivot Pin 1" x 4.44" Plated Pin Weldment Handle Lynch Pin 1/4" Carriage Bolt 3/8"-16NC x 1" Gr Clevis Pin 5/8" x 4" Hitch Pin Clip.148" x 2-3/4" Hardened Flatwasher 3/8" Acorn Lock Nut 3/8"-16NC Grease Fitting Straight 1/4" Decal Warning Decal Warning Decal Danger Decal Warning Decal Warning Decal Caution

74 27. HYDRAULIC CYLINDERS, HOSES, AND TUBELINES

75 HYDRAULIC CYLINDERS, HOSES, AND TUBELINES Reference Description Part No. Qty Cylinder, Tilt Cylinder, Lift Hose Cover Sponge Rubber 5-1/2" Hydraulic Hose Assembly 3/8" x 69" LHLCBE (1220) Hydraulic Hose Assembly 3/8" x 78" LHLCBE (1220 HL) Hydraulic Hose Assembly 3/8" x 89" LHLCRE (1220) Hydraulic Hose Assembly 3/8" x 98" LHLCRE (1220 HL) Hydraulic Hose Assembly 3/8" x 55" LHTCBE (All Models) Hydraulic Hose Assembly 3/8" x 57" LHTCRE (All Models) Hydraulic Hose Assembly 3/8" x 32" RHLCBE (1220) Hydraulic Hose Assembly 3/8" x 42" RHLCBE (1220 HL) Hydraulic Hose Assembly 3/8" x 53" RHLCRE (1220) Hydraulic Hose Assembly 3/8" x 63" RHLCRE (1220 HL) Hydraulic Hose Assembly 3/8" x 17" RHTCBE (All Models) Hydraulic Hose Assembly 3/8" x 29" RHTCRE (All Models) Hydraulic Hose Assy 3/8" x 116" Tee to Valve (All Models) Fitting Tee Flatwasher 5/16" Locknut Nylon 5/16"-18NC Grease Fitting Straight 1/4" Tie Strap Blue.14" x 5.5" Tie Strap Red.14" x 5.5" Tie Strap Yellow.14" x 5.5" Tie Strap Green.14" x 5.5" Tie Strap Black 5/16" x 14" Hose Sock 1.59" x 63" Fitting ¾ JICM x ¾ ORBM Side Hose Cover Top Hose Cover (1220) Top Hose Cover (1220 HL) Fitting ¾ JICM x ¾ ORBM

76 28. LIFT CYLINDER (CROSS) 2.75 x 1.50 Rod x Stroke Reference Description Part No. Qty Lift Cylinder (complete) Tube Assembly...NSS Nut Piston Seal Kit Gland Rod Assembly...NSS Grease Fitting Straight

77 29. TILT CYLINDER (BAILEY) 2.25 x 1.25 Rod x Stroke Reference Description Part No. Qty Tilt Cylinder (complete) Tube Assembly...NSS Nut Piston Seal Kit Gland Rod Assembly...NSS Grease Fitting Straight Grease Fitting Piston O-ring 5 4 Rod Seal 4 Wiper Seal Wear Ring 4 Piston Seal 1 4 Gland O-ring 4 Backup Ring 6 4 Gland Outer O- ring 77

78 30. MID MOUNT COUPLER KIT

79 MID MOUNT COUPLER KIT Reference Description Part No. Qty Quick Coupler Mount (Some Models) Quick Coupler, Female Quick Coupler, Male Fitting Bulkhead with Nut O-Ring Rubber Coupler Plug Hex Head 1/2"-13NC x 1.50" Gr Hex Nut 1/2"-13NC Flatwasher 1/2" Hardened Hydraulic Hose Tie Strap Green.14" x 5.5" Tie Strap Blue.14" x 5.5" Tie Strap Red.14" x 5.5" Tie Strap Yellow.14" x 5.5" Tie Strap Black 5/16" x 14" Lockwasher ½

80 31. LOADER VALVE 2 SPOOL (Load Sense) 80

81 LOADER VALVE 2 SPOOL (Load Sense) Reference Description Part No. Qty Valve Spool 2 Spool (load sense) Section 1 Kit Housing...NSS O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Spool...NSS Load Check Float Detent Kit End Cap Cap Screw M6 x 90 Internal Socket Head SK*... Seal Kit Section Section 2 Kit Housing...NSS O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Spool...NSS Load Check Spring Center Kit End Cap Cap Screw M6 x 40 Internal Socket Head SK*... Seal Kit Section Section Inlet Kit Housing...NSS Plug 7/8"-14 Internal Socket Head Plug Cap Screw M8 x 30 Internal Socket Head Mounting Bracket Hex Nut M Plug BSPP 1/4" Internal Socket Head Section Outlet Kit Housing...NSS O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Plug Power Beyond Cap Screw M8 x 30 Internal Socket Head Mounting Bracket Hex Nut M SK*... Seal Kit Section Tie Rod Kit, 2 Spool

82 32. LOADER VALVE 2 SPOOL (Open/Closed Center) 82

83 LOADER VALVE 2 SPOOL (Open/Closed Center) Reference Description Part No. Qty Valve Spool 2 Spool (load sense) Section 1 Kit Housing O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Spool Load Check Float Detent Kit End Cap Cap Screw M6 x 90 Internal Socket Head SK*... Seal Kit Section Section 2 Kit Housing O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Spool Load Check Spring Center Kit End Cap Cap Screw M6 x 40 Internal Socket Head SK*... Seal Kit Section Section Inlet Kit Housing Plug 7/8"-14 Internal Socket Head Plug Cap Screw M8 x 30 Internal Socket Head Mounting Bracket Hex Nut M Plug BSPP 1/4" Internal Socket Head Section Outlet Kit Housing O-Ring 2.62 x drom O-Ring 2.62 x drom O-Ring 2.62 x drom Plug Power Beyond Cap Screw M8 x 30 Internal Socket Head Mounting Bracket Hex Nut M SK*... Seal Kit Section Tie Rod Kit, 2 Spool... 1 A... Closed Center or Power Beyond Plug Kit... NOTE: If your unit is equipped with open or closed center loader valve, contact factory for service parts. ed center loader valve, contact factory for service parts. 83

84 33. JOYSTICK CONTROLLER Reference Description Part No. Qty Joystick Controller with 2 Switches with Cables Joystick Controller with 2 Switches Cables 2000mm Switch Handle Cable Adaptor kit

85 34. SKID STEER BUCKET 1 Reference Description Part No. Qty Bucket 72" Standard Bucket 78" Standard Bucket 84" Standard

86 35. LOADER VALVE Serial Number and older Load Check Locations 6 86

87 LOADER VALVE Serial Number and older Reference Description Part No. Qty Loader Valve (complete)... w/ Direct Mount Joystick Loader Valve (complete)... Use with tractor supplied cables and controller Spool, Regen...NSS Spool, Float...NSS Body Machining...NSS Spool End Float Kit Spool End Regen Kit Load Check (One per kit, two kits required) Relief Cartridge (180 Bar 2610 PSI) Seal Kit * * NOTE: Seal kit includes all seals for all valve components 87

88 4 36. LOADER VALVE Serial Number and newer LOADER VALVE Serial Number and newer Reference Description Part No. Qty Loader Valve (complete)... w/ Direct Mount Joystick Loader Valve (complete)... Use with tractor supplied cables and controller Spool, Regen...NSS Spool, Float...NSS Body Machining...NSS Spool End Float Kit Spool End Regen Kit Load Check (One per kit, two kits required) Relief Cartridge (180 Bar 2610 PSI) Seal Kit * * NOTE: Seal kit includes all seals for all valve components 7 1 Identify valve part number before ordering service parts. Valve can also be identified by boot shape. DO6DZF2CEAAZ

89 37. CONTROL HANDLE COMPONENTS Serial Number and older

90 CONTROL HANDLE COMPONENTS Serial Number and older Reference Description Part No. Qty Joystick Complete Kit (Contains all parts except Lever) Joystick Lever Knob Control Handle Boot Pivot Pin Lockwasher M Allen Head Screw M6 x Pivot Pin Handle Plate Handle Coupler Nut Nut M Zip Tie Spring Clip (Located on ends of Pivot Pins) Flat Allen Head Screw M6 x Connector Pivot Pin Nut M Base Plate Flat Allen Head Screw M6 x Spool Eye Handle Cover

91 38. CONTROL HANDLE COMPONENTS Serial Number and newer CONTROL HANDLE COMPONENTS Serial Number and newer Reference Description Part No. Qty Joystick Complete Kit (Contains all parts except Lever) Joystick Lever Knob Control Handle Boot Pivot Pin Kit Zip Tie Base Plate Kit...NSS... 1 Note: Identify valve and valve controller before ordering service parts. 91