JODALE PERRY. Parts List & Mounting Instructions. Jacobsen HR9016 JDP BUILT FOR LIFE

Transcription

1 JODALE PERRY Parts List & Mounting Instructions Jacobsen HR9016 JDP BUILT FOR LIFE

2 Jacobsen HR9016 Mounting Instructions Standard Parts 1 - LH Rear Mounting Bracket 1 - RH Rear Mounting Bracket 1 - Front Mounting Bracket 1 - Rear Panel 1 - Platform Floormat 1 - LH Underseat Floormat 1 - RH Underseat Floormat 1 - Standard Acoustic Foam 1 - Step Pad 1 - Hydraulic Pedal O-Rubber Page1

3 Jacobsen HR9016 Mounting Instructions 4 - Structural Washer 1-50 Amp circuit Breaker # w/jumper wire installed 1 - Seat Belt Assembly # C6180AS 1 - ¼ Yellow Loop 1 - ½ Yellow Loop 30 - ¾ x ¾ NDAX 32-1 x 1 NDAX 36 - ½ x ¾ NDAX Standard Bolts 2-5/8 x 2 Hex Bolt, Gr ¾ I.D. Rubber Isolator 4-5/8 x 4 Hex Bolt, Gr ¾ ID Rubber Washer 6-5/8 Lock Nut 1 - ½ x 1 ½ Hex Bolt, Gr ½ x 2 Hex Bolt, Gr ½ Lock Washer 2 - ¼ x 3/4 Flange Bolt 2-3/8 x 1 ½ Hex Bolts Page 2

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6 Jacobsen HR9016 Mounting Instuctions 1-4 ½ x 8 Font Steering Pump Mylar 1-4 ½ x 6 Rear Steering Pump Mylar 1-7/14 x 26 1/8 Lower Hydraulic Tank Cover Mylar /16 x 33 ¾ Upper Hydraulic Tank Cover Mylar 1-16 x 23 Rear Shield Mylar - Installed 1-15 x 22 Front Hydraulic Cover (Notched) 1-4 x 9 Rear Steering Column Upholstery 1-7 x 24 Rear Steering Column Front Mylar L&R - 9 ¼ x 17 ½ Side Steering Column Mylar 1 - Radiator Sound Barrier w/mylar 1-6 x 13 Tank Rear End Cover Mylar Road Light Kit 1 - Signal Switch 1 - Front Road Light Bar 1 - HS-20 Gear Clamp AND Bracket 2 - Head Light Speaker # 900F/H94-12V 1 - Red Tail Light 1 - Tail Light Mount 1-5/16 x 1 Hex Bolt 1-5/16 Flange Nut 1-5/16 Fender Washer 4 - Flasher Lights Page 5

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10 10. Installing Underseat NDAX. Take the 1 x 1 NDAX (1) and place it on the seat mount. Start at the back and work your way forward until you reach the left tank mount (2). See Figure 6. Take the ¾ x ¾ (3) NDAX and place Figure 6 Jacobsen HR9016 Mounting Instructions 12. With the remaining 1 x 1 NDAX, split it into two 8 lenghts. Peel the backing off of on piece and sitck it on to the other (5). Move the new piece into position on the left side of the machine between the break cables and the left tank. See Figure 8. Figure it along the seat mount, starting where the 1 x 1 NDAX ended, work your way up to the platform mount (4). See Figure 7. Figure Repeat step 10 for the right side Installing the optional turn signal/flasher switch. If your cab has the optional turn signal/flasher, remove the front casing from the steering tower. Route the wiring from the bottom right front post, up through the opening at the base of the steering tower and up the steering column. Ensure that the wiring does not interfere with any moving parts under the foot platform in the steering tower. Secure the signal switch to the steering column with bracket and hose clamp and connect the wiring. 14. Installing standard acoustic foam. Remove the front casing of the steering tower. Move the foam into position inside the tower (6). Once the foam is in place, peel off the backing and secure it into place with the adhesive side. See Figure Installing optional noise reduction package. If your cab comes with the optional acoustic foam install it now. Remove the front platform from the unit. Take the piece of front platform Page 9

11 Jacobsen HR9016 Mounting Instructions Figure 9 8 the pump (8). Once in place remove the backing and secure in to place. See Figure 9. Take the rear steering column mylar and attach the steering column floormat to the top of it. Then take it and glue into position inside and at the front of the steering column. Make sure that the upholstery slit is at the top of the column (9). Next glue the two side pieces into postion on the inside sides of the steering column (10). See Figure mylar and move it into position. It should fit with 1 of clearance between the edge of the foam and the center of the slots. Once in place peel off the backing and secure the adhesive side into place. Reinstall the front platform. Take the rear underseat plate and move it into position with the mylar facing down, on top of the seat mount. Line up the holes in the shield with the holes in the seat mount (7). Take the front underseat plate and move it to position in front of the rear underseat shield with the mylar facing down. Line up the holes in the shield with the holes in the seat mount. See Figure 10. Next Figure Figure 11. Take the two pieces of hyd. Tank mylar and move them in to position on the upper and lower parts of the tank (11). See Figure 12. Figure 12 7 take the two pieces of steering pump mylar and move them into position in front of and around Once in place remove the backing and secure into place. Take the right side tank end mylar and Page 10 11

12 move it into position at the back of the the right side console, between the seat mount the right tank and the top of the right console (12). Once it has been located correctly, peel off backing and stick into place. See Figure 13. Figure 13 Jacobsen HR9016 Mounting Instructions bolts and lockwashers on left hand side under platform. Insert a rubber isolator (16) in the mounting bracket isolator cups. See Figure 14. Figure Installing Hydraulic Tank. Slide hydraulic tank back in position Tighten front ½" carriage bolt and hardware (X) and install and tighten rear ½" hardware (V). Lift rear tank mount into position and secure to right rear mounting bracket and cross frame with 3/4"hardware (Z). Torque nuts to ft.lbs. Install rear and tighten front 5/16" fender wall hardware (U). Install fender with (4) 5/16" screws and hardware (S). Install clamps securing 2" pump suction line. See Figures 4 and Installing front mounting bracket. Bolt the front mounting bracket (13) over the front lip of the foot platform using the 3/4" bolts (14) and corresponding hardware. Find the two ½" nuts welded onto the left and right sides of the bracket. Mark the hole locations on the side lips of the foot platform and remove the front bracket. Drill two 9/16" holes through the lip of the foot platform at the marked locations. Loosely bolt the front bracket to the machine using ½ x 1 ½ bolts (15) and lock washers on right hand side under the platform. Use ½ x Installing Fuel Tank. Place fuel tank back on tractor. Install (2) ½" carriage bolts and hardware (L) from frame to fuel tank and fender wall. Lift rear tank mount into position and secure to left rear mounting bracket and cross frame with 3/4" hardware. Torque nuts to ft.lbs. Install 5/16" hardware (M) securing fender wall to tank mount. Reconnect wires to fuel sender (J) and fuel lines to tank. Install fender with (4) 5/16" screws and hardware (H). See Figure 2. C. PREPARING THE CAB IMPORTANT! The side panels and roof are not structural Do not handle the cab in any way using the side panels or the roof. 19. Installing cab weather stripping. For the left side panel, install 180 bulb seal (17). Starting at the left front lower corner of the inner steel side panel. Work your way back until you reach the foam rubber seal at the rear corner of the steel panel. See Figure Repeat step 16 for the right side. Page 11 16

13 Jacobsen HR9016 Mounting Instructions Figure 15 Remove bolts securing cab to pallet. Lift cab with hoist. See Figure 16. Figure Removing the door and side windows. Release the gas shock from the cab frame by removing the wire snap ring and pulling front end of gas shock down. Open the door and lift it straight up off of the hinge pin. Be careful not to lose the brass washers. Remove front right window by opening window latch to half-open position and pulling latch down so that stud passes through slot in top surface of the latch. Open the window and lift it straight up off of the pin hinge. Be careful not to lose the brass washers. If you do not have the optional cab lifting bracket, it will probably be necessary to remove the side windows. Open side window and remove Rue Ring Cotter from clevis pin. Slide slider off of clevis pin. Lift off side window. Be careful not to lose the brass washers. 22. Installing the cab lifting bar. If you have the optional cab lifting bar, then pass the cab lifting bar through the door opening and the escape window opening (18). Position the lifting bar against the front surfaces of both hinge posts and slide it upward so that rubber padded brackets hook around the inside of each hinge post. Attach lifting bar to hoist, ensuring that lifting bar, chains or cables will not damage cab roof. D. BEGINNING CAB INSTALLATION 23. Lowering the cab. Begin lowering the cab carefully onto the tractor, guiding rear mounts between tanks. Ensure that fuel and oil filler spouts clear the cab side panels. Ensure that heater hose does not become pinched under cab. Lower the cab until the cab mounts are resting on the rubber isolators in the front and rear bracket isolator cups. Insert the four 5/8 x 3 ½ bolts (19) into the mounts from above. From below, first slip on the rubber washer (20), then the thick square structural washer (21), and finally the 5/8 nut (22). IMPORTANT!! The structural washer is crucial to the structural integrity of the ROPS frame. It must be installed between the bottom surface of the mounting brackets add the nut. Otherwise the nut could be pulled through the mounting bracket during a rollover and protection would be lost. Torque nut to compress isolator until distance between top plate of bracket and bottom plate of mount is 1-1/8". See Figure 17. Torque 5/8" bolts through front surface of front mounting bracket to ft. lbs. At front left mounting bolt, tuck floor mat under the cab frame cross-member at the bottom of the windshield. Page 12

14 Jacobsen HR9016 Mounting Instructions Remove but do not discard the cab lifting bar. It will be required for future cab installations. Figure 17 Figure Inspect the gap between the fiberglass side panels and the plastic fuel and hydraulic oil tanks. Wedge in rubber spacers, if necessary (not supplied) to ensure that the side panels do not touch the tanks. If the side panels are allowed to contact the tanks, vibrations may cause the panels to wear holes in the tanks. E. INSTALLING OPTIONS 25. Installing optional outside mirrors. Bolt the mirror bracket (23) to the outside surface of the hinge post. The top lip of the mirror bracket should hook over the top of the hinge post and the mirror mounting bar should angle towards the rear of the cab. Bolt the mirror to the mirror bracket using the 5/16"x 3/4" bolts (24) supplied. See Figure Installing the optional heater. Install Heater high pressure hose. Drain radiator coolant. Locate the 5/8"ID heater hose exiting the base of the left side panel (25). Route the hose along the tractor frame on the left side inside of the engine compartment. Tie down the hose as required to ensure that it does not interfere with controls, levers, accessories or any other moving or hot parts. Locate the port on the rear upper end of the engine coolant manifold (26). Remove the plug from the port, and install the adapter fitting. Install the 3/8-n.p.t. 5/8" 90 elbow into the other end of the fitting (27). REMEMBER to use a water sealant material on the threads of the elbow. Measure off the distance to the elbow and cut the hose (allow for some excess). Connect the hose to the elbow using one of the HS-10 (28) hose clamps provided. See Figure 19. Figure Install low pressure hose. Locate the remaining 5/8"ID heater hose (29) exiting the base of the right side panel. Locate where the Page

15 lower radiator hose is connected to the water pump inlet. Route the 5/8"ID heater hose to the lower radiator hose. Tie down the hose as required to ensure that it does not interfere with controls, levers, accessories or any other moving or hot parts. Cut the radiator hose approximately 8" from the water pump inlet (as measured along the hose, and as shown in Figure 20 (30). Install splicer (31) using the HS32 hose clamps (32) provided. Install the 3/8-N.P.T. x 5/8" 180 barb fitting (33) into the splicer. REMEMBER to use a water sealant material on the threads of the fitting. Measure off the distance along the suction hose to the barb fitting and cut the suction hose (allow for some excess). Connect the suction hose to the barb fitting using the HS-10 hose clamp (34) provided. See Figure 20. Figure 20 Jacobsen HR9016 Mounting Instructions ground located on the rear left side of the engine. Make sure that the wire does not interfere with and moving parts of the engine. See Figure 21. Figure Take the loose end of the jumper wire and attach it to the machine power source (36). Take the cab power wire and the breaker and attach them to the machine power source below the jumper wire connection (37). Make sure that the power wire does not interfere with any moving parts of the engine. See Figure 22. Figure Replace coolant. Ensure that all connections are tight and then replace the radiator coolant. Open the water valve, using the rotary control in the switch plate of the cab and turn on the fan. Start the machine s motor and run at PTO rpm for 5 minutes. Once the heater begins to heat, stop the motor, check for leaks and add antifreeze as required. Start the unit again and run at PTO rpm for a few minutes to remove any air trapped in the heater hose. Stop the unit again, check the antifreeze and add as required. 29. Attaching the power wires. Take the cab ground wire (35) and run it to the machine 30. Installing the optional wiper washer. Install the washer tank brackets. Locate the water reservoir tank in the rear of the engine Page 14 37

16 Jacobsen HR9016 Mounting Instructions compartment. Remove the front bolt from the reservoir tank, place the tank bracket (38) over the hole. Using the bracket as a guide, mark and drill a 3/8 hole into the plate directly below the top hole. Reattach the top bolt. Fasten the bracket in the bottom using a 3/8 x 1 hex bolt (39) and a 3/8 flange nut. If the cab is equipped for two washer tanks, remove bolt from solenoid to rear of water reservoir tank. Follow the same mounting procedure as above. Route the wiper washer hose and wiring from the cab to the washer tank. Secure the hose and wiring so that they do not come into contact with any moving or hot parts. See Figure 23. Figure place using the 5/16 bolt, 5/16 washer and 5/16 nut (40). Attach the tail light to the bracket using the hardware provided. Route the wiring from the back of the cab to the hood hinge, and underneath the hood by the radiator to the tail light. Connect all wires to the wires on the lights. Attach the ground loops to the mount threads on the lights. See Figure 24. Figure Installing the optional road light and work light kits. Remove the two ¾ bolts from the front mounting bracket. Take the road light bar and move it into position where the holes in the mounting bracket are. Secure the bar into place using the same bolts as before. Attach the two road lights to the inside mounting tabs on the bar. Attach the two signal lights to the two outside mounting tabs. Take the signal switch and mount it to the steering column using the gear clam provided. To mount the work lights, take the lights provided and attach them to the brackets in the front and the rear of the headliner. To attach the tail light to the rear of the engine hood, take the tail light bracket and secure it into F. COMPLETING CAB INSTALLATION 32. Installing seat. Install seat belt assembly on the seat using the instruction sheet provided with the belt and Figure 25. Install seat pan assembly using (4) 3/8" screws and corresponding hardware (R). Connect wire harnesses. Install floorboard using (4) 7/16" truss head screws (P). Install heat shield to hydraulic tank with (3) 5/16" screws, lockwashers and washers (N). See Figure Finishing Tractor Re-assembly. Cut out shaded areas of machine floor shield as shown in Figure 26 to provide clearance for rear mounting brackets. Secure cab rear panel with two ¼ x ½" flange bolts (41). Replace machine floor shield. Tuck the front lip of the floor shield into the channel provided in the rear surface of the cab rear access panel(42). See Figure 27. Page 15

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18 Jacobsen HR9016 Mounting Instuctions Figure 29 Figure Figure 30 the pedal off the unit and remove the rubber pads. Take the rubber pads and attach them to the new hydraulic pedal (48). Attach the new pedal to the unit using the same hardware that was removed (49). See Figure Figure Installing the step. Remove the two bolts on the left wing of the front deck, where the step fits under a support bracket. Replace those bolts with the two 3/8 x 1 ½ hex bolts (46) supplied. Place step (47) over the bolts positioning it to the front and outside of the original step. Secure into place using the nuts removed from the support bracket. See Figure Installing the hydraulic pedal. Remove the fastening hardware from the factory pedal. Take 38. Refill fuel tank. Refill fuel tank being sure to follow all safety precautions listed earlier. Inspect all hardware regularly and tighten as required. In the event of damage or alteration, the ROPS must be replaced prior to further operation of the machine. Page 17

19 Jacobsen HR9016 Mounting Instuctions All labels, caution decals, and ROPS serial no. plate data must be kept intact and legible. Page 18

20 Jacobsen HR9016 Mounting Instuctions F. Air Conditioner Installation Instructions 39. Installing the Rooftop Air Conditioner and A/C Interior Cover. Remove the four nuts holding down the cab roof and retain for re-use. Lift the roof off of the headliner. A cutout template for the roof is provided with the air conditioner. From above, center the template over the upholstered part of the headliner, directly above the seat. The air conditioner will need to be oriented with the hoses exiting toward the rear, near the rear left window post (i.e. left with respect to the seated operator). Position the template so that, after cutting, there will be equal amounts of upholstery showing in front and in back of the cutout. Mark the cutout on the headliner. Cut through the headliner and its upholstery at the marked location. Be careful not to cut any wires or heater hoses inside the headliner. If the cab is equipped with the optional beacon, disconnect the wiring to the beacon and remove the beacon from the roof. Keep all fasteners for re-use. Lengthen the lead and ground wiring from so that it extends from the switch to about 6 beyond the left rear corner of the headliner. Install end connectors on the lead and ground wires. Place the roof back onto the headliner. Mark the location of the roof cutout directly above the headliner cutout. Remove the roof and lay the template into the inside of the roof. Mark, drill holes and cut the roof opening according to the template. Install the rooftop A/C unit onto the roof according to instructions supplied with the air conditioner. Reinstall the roof (with A/C unit installed) back onto the headliner. Remove the air conditioner s partition plate, retaining it and its fasteners for re-use. Secure the air conditioner partition extension panel to the bottom of the roof top unit using the fasteners provided in this adapter kit. Now secure the partition plate to the partition extension panel using the original partition plate fasteners. Install the A/C interior cover to the underside of the headliner according to instructions supplied with the air conditioner. 40. Installing the Compressor. Remove the fan belt idler and fan mount, retaining the bolts for re-use. Replace existing fan belt with A54 fan belt. Put the fan mount back in place and install the compressor bracket on top of the fan mount using three fan mount bolts (50) and one of the idler bolts (51). Attach the bracket arm to the remaining idler mount bolting location using the remaining idler bolt (52). See Figure 33. Bolt Figure the compressor loosely to the compressor bracket using two 3/8 x 1-1/2 bolts and matching 3/8 lock nuts (53) from the adapter kit. Bolt the compressor loosely to the bracket arm with one 3/8 x 1-1/2 bolts and matching 3/8 lock nut (54). See Figure 34. Adjust the compressor and bracket arm to set belt tension, and then tighten bolts to secure the compressor. 41. Installing the Air Conditioner Hoses and Electrical Leads. Crimp the straight female fittings onto the hoses and attach the hoses to the rear of the roof top air conditioner unit. Route the hoses, and the power and ground leads down the outside edge of the left rear window post of the cab. Remove the two black step bolts that fasten the left side of the rear window. Retain the rubber bushings and acorn nuts for re-use. Secure the hoses and electrical leads to the rear post using the clips (55) provided with the air conditioner, the longer 1/4" x 1 1/4" black step Page 19

21 Jacobsen HR9016 Mounting Instuctions Figure Figure bolts from the A/C adapter kit (56) (See Figure 35), and the rubber bushings and acorn nuts Figure provided with the cab. Route the hoses to the compressor, ensuring that the hoses do not come in contact with hot or moving parts, or interfere with service access locations. Secure the hoses as necessary with pull ties. Install the female elbows onto the hoses and attach the hoses to the compressor (Figure 36). Ensure that the air conditioner ground wire is securely grounded to the tractor frame. Install the inline fuse holder and fuse into the power lead and connect the lead to the cab circuit breaker. Ensure that the electrical leads do not come in contact with hot or moving parts, or interfere with service access locations. Secure the leads as necessary with pull ties. 42. Charging the Air Conditioner. Charge the air conditioner system with R-134a refrigerant using the procedure recommended by the Kysor Westran and in accordance with all applicable regulations. 43. Installing the Air Conditioner Cover. Remove the bolts securing the top lid of the roof top air conditioner. Leave the lid in place and keep the bolts for re-use. Put air conditioner cover over the air conditioner so that the opening in the cover is aligned with the air conditioner fan. If the cab is equipped with the optional beacon, then reinstall the beacon on the air conditioner cover just behind the air conditioner fan opening. Lengthen the wiring on the beacon so that it reaches down to the power and ground leads at the left rear corner of the headliner. Route the wiring under the A/C cover and secure it to the A/C hoses. Attach end connectors and connect to power and ground. Secure the air conditioner cover to the top lid of the air conditioner re-using the original air conditioner Page 20

22 lid bolts. Trim the air conditioner cover as necessary to clear the air conditioner hoses. See Figure 37. Figure 37 Jacobsen HR9016 Mounting Instuctions Page 21

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