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LeeBoy LBC-24W Operation, Service And Parts Manual

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O O P P E E R R A A T T I I O O N N S S , , S S E E R R V V I I C C E E
A A N N D D P P A A R R T T S S M M A A N N U U A A L L
LBC-24W Curber
Manual No. 986621-01
For Units with Serial No. 41933 and higher
Published 09-31-06

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  • Page 1 O O P P E E R R A A T T I I O O N N S S , , S S E E R R V V I I C C E E A A N N D D P P A A R R T T S S M M A A N N U U A A L L LBC-24W Curber Manual No. 986621-01 For Units with Serial No.
  • Page 2 Lincolnton, NC 28092 Tel: 704-966-3300 Fax: 704-483-5802 www.LeeBoy.Com USERS’ REFERENCE GUIDE DELIVERY DATE _______________________________________________ UNIT SERIAL NUMBER _________________________________________ ENGINE TYPE ________________________________________________ ENGINE NUMBER _____________________________________________ DEALER'S NAME AND ADDRESS _____________________________________________________________ _____________________________________________________________ PHONE NUMBER ______________________________________________ EQUIPMENT HOURS ___________________________________________ SERVICE MANAGER ___________________________________________ LBC-24W Curber...
  • Page 3 5. LeeBoy has the right to repair any component 5. Unreasonable delay, as established by or part before replacing it with a new part. LeeBoy, in making the applicable units or parts 6.
  • Page 4 This manual should be used with all related supple- If any questions arise concerning this publication or mental books, engine manual, and parts book. others, contact your local LeeBoy Distributor for the Related Service Bulletins should be reviewed to pro- latest available information.

  • Page 5: Table Of Contents

    TRANSPORTING THE LBC-24W CURBER ........

  • Page 6: Introduction & Safety

    RECEIVING THE LBC-24W CURBER ........

  • Page 7: Forward

    This manual contains the correct operation and routine maintenance procedures needed by the owner/opera- tor for the safe and efficient use of the Leeboy LBC-24W Curber. In order to maximize the performance and efficiency of the Curber, it is VERY IMPORTANT that the owner/operator and maintenance personnel read this manual thoroughly before operating or servicing the machine.

  • Page 8: Overview Of The Manual

    OPERATION Refer to OPERATION, Section 3 in this manual, for information needed to operate the Model LBC-24W Curber safely. The operator of this equipment should READ, UNDERSTAND, and FOLLOW the operating instructions. Cautions are provided in the front of this manual and in the OPERATION section.

  • Page 9: Precautionary Instructions

    In addition, some machines use or contain hazardous chemicals which may require a specific Material Safety Data Sheet (MSDS). If such information is necessary for the safe operation of this machine, those MSDSs are included on the following pages. LBC-24W Curber...

  • Page 10: Safety Decals

    NOTE: It is the responsibility of the owner and operator to make sure that all decals are readable and located on the machine as designated by the manufacturer. FIGURE 1-1. DECALS AND DECAL LOCATIONS LBC-24W Curber...

  • Page 11: Safety

    Remote Controls at the left front of the machine. In the event of an emergency, push the button to shut down all machine operations. Refer to Engine Start Up in OPERATION for procedures to re-start the engine. FIGURE 1-2. EMERGENCY STOP BUTTONS LBC-24W Curber...

  • Page 12: Operating Safety

    DO NOT change tires unless the machine is supported by approved jacks and jack stands. DO NOT inflate tires. Tires are filled with silicone. DO NOT hammer on rims with steel hammers. Use rubber, lead, plastic or brass faced mallets. DO NOT mount a tire without the proper equipment and experience. LBC-24W Curber...

  • Page 13: Handling Fluids Safely

    BE SURE the unit is stored in an area that is firm, level and free of debris. STORE the machine inside a building, or cover it with a weather-proof tarpaulin and support the wheels securely. Refer to MAINTENANCE, Section 4, for more detailed instructions. LBC-24W Curber...

  • Page 14: General Information

    TABLE 2-7. MACHINE SYSTEM CAPACITIES ........2-10 TABLE 2-8. FUEL AND LUBRICANT SPECIFICATIONS .......2-10 LBC-24W Curber...

  • Page 15: General Information

    The descriptions and specifications given in this filters intake air before use by the engine. The air section are applicable to the LBC-24W Curber. This cleaner removes fine particles such as dust, sand, section contains a description of how the major chaff and lint from the air (Figure 2-2).

  • Page 16: Filters

    A warning light mounted on the control panel warns Refer to the engine manufacturer's manual for a complete description of the engine. the operator if the battery rate falls to a critical level (Figure 2-6). FIGURE 2-4. ENGINE OIL FILTER FIGURE 2-6. WARNING LIGHTS LBC-24W Curber...

  • Page 17: Hydraulic System

    (Figure 2-8). control the Curber functions. FIGURE 2-7. HYDRAULIC PUMP FIGURE 2-8. HYDRAULIC RESERVOIR LBC-24W Curber...

  • Page 18: Drive System

    SPECIFICATIONS DRIVE SYSTEM stops rotating the drive motors allowing the machine to slow and stop. The LBC-24W drive system includes three hydro- static variable speed hydraulic motors, control valve Steering assembly, electronic flow control valve, The front drive wheel is also used for steering the combiner/divider assembly, and a counterbalance machine.

  • Page 19: Hopper

    The oper- Knobs, mounted on the Main Control Panel, control ator will make this decision based on the consisten- vibrator speed. cy of the concrete being used. FIGURE 2-10. HOPPER FIGURE 2-11. MOLD LBC-24W Curber...

  • Page 20: Control Sensors

    (Figure 2-13). FIGURE 2-13. TOP-CON CONTROL SYSTEM LBC-24W Curber...

  • Page 21: Leveling Blade And Auger

    • Washdown System road surface providing a level operating surface for • Driveway Cutter the machine. The auger removes graded material • Vector Thrust Cylinder from underneath the machine (Figure 2-14). FIGURE 2-14. AUGER AND LEVELING BLADE LBC-24W Curber...

  • Page 22: Specifications

    Section 2 SPECIFICATIONS SPECIFICATIONS Tables 2-1 through 2-8 list the engine and system specifications for the LBC-24W Curber. Additional maintenance specification charts can be found in Section 4, MAINTENANCE. TABLE 2-1. ENGINE SPECIFICATIONS ITEM SPECIFICATION Model Kubota Diesel Turbo V1505T...
  • Page 23 TABLE 2-8. FUEL AND LUBRICANT SPECIFICATIONS ITEM SPECIFICATION Engine Oil See engine manufacturer's manual Hydraulic Oil AW32 Coolant 50/50 water/ethylene glycol or propylene glycol Fuel Diesel, local low-sulfur blend Grease Shell Avania EP Grease Gear Oil 50W Gear Lubricant 2-10 LBC-24W Curber...
  • Page 24 TRANSPORTING THE LBC-24W CURBER ........

  • Page 25: General Information

    LBC- 24W Curber. The operating controls for the LBC-24W Curber are shown in Figures 3-1, 3-2, and 3-3. Their functions are listed in Tables 3-1, 3-2, and 3-3. The controls...
  • Page 26 Section 3 OPERATION FIGURE 3-1. MAIN CONTROL PANEL LBC-24W Curber...
  • Page 27 Left/Neutral/Right momen- Used to manually control tary three-position toggle machine steering. switch Steering Computer ON/OFF two-position toggle Used to activate computer con- Switch switch trolled steering. Steering Computer Indicator light When illuminated indicates com- Light puter steering is selected. LBC-24W Curber...
  • Page 28 Left Vibrator Switch ON/OFF two-position toggle Used to activate the hopper left switch vibrator. Right Vibratory MIN - MAX rotating knob Used to control vibration emit- Speed Control ted by the hopper right vibrator. LBC-24W Curber...
  • Page 29 Auger Drive Switch ON/OFF two-position toggle Used to activate the auger switch drive. Grading Blade Up/Neutral/Down momentary Used to lift and lower the grad- Switch three-position toggle switch ing blade. LBC-24W Curber...
  • Page 30 Indicator light Illuminates when ignition is in the RUN position without start- ing engine to test operation. Illuminates during engine opera- tion to indicate high engine coolant temperature. Option Used to install optional equip- ment or warning device. LBC-24W Curber...
  • Page 31 Emergency Stop ON/OFF push/pull knob When pushed all machine oper- ations stop. Used as a safety device to stop machine in case of an emergency situation. Pull to reset. LBC-24W Curber...

  • Page 32: Preliminary Procedures

    9. Perform service intervals as indicated in 2. Check the engine oil and coolant frequently. Section 4. 3. Operate engine at normal loads. 10. Check engine manufacturer's manual for addi- tional information of engine break-in. 4. Check indicators and gauges frequently during operation. LBC-24W Curber...

  • Page 33: Pre-Start Inspection

    2. Operate engine at less-than-normal load and Refer to engine manufacturer’s manual for instruc- speed until engine reaches normal operating tions when starting engine for the first time. Follow temperatures. engine manufacturer's recommendations for fuel and oil. 3-10 LBC-24W Curber...

  • Page 34: Cold Weather Engine Start Up

    GENCY STOP button to reset. 3. Refer to ENGINE START UP on the previous page for control settings before re-starting the engine and resuming operations. NOTE: The electrical system is 12 volts with negative (-) ground. Use only 12-volt booster battery. LBC-24W Curber 3-11...

  • Page 35: Driving The Machine

    See BRAKING the local authorized dealer for engine settings and Braking on the LBC-24W Curber occurs when auto- modifications. matic operation is released by placing the Top-Con Power switch (Figure 3-1, item 5) in the OFF posi-...

  • Page 36: Machine Preparation

    3. Make sure all wiring harnesses and auxiliary travel in both directions. port hydraulic hoses are moved out of the mold installation area. ATTENTION: If the hopper vibrators are installed during mold installation, be careful not to damage the vibrator during mold installation. LBC-24W Curber 3-13...

  • Page 37: Using The Top-Con System

    To work in the FIGURE 3-7. CONTROL PANEL 3-14 LBC-24W Curber...

  • Page 38: Menu Selection Soft Keys

    The desired setting can be set by turning the left grade knob. operator a single switch to control both left and right grades. FIGURE 3-8. BASIC OPERATION FIGURE 3-9. CONTROL MODE FIGURE 3-10. ELEVATION/SLOPE INDICATION LBC-24W Curber 3-15...

  • Page 39: Setup Mode

    53 and the slope gain is 14. This sets the minimum signal (voltage) required to operate the hydraulic valves. Start by raising the FIGURE 3-11. SLOPE DIRECTION FIGURE 3-12. ELEVATION AND SLOPE GAIN FIGURE 3-14. ADJUST VALVE OFF-SET FIGURE 3-13. SET-UP MENU 3-16 LBC-24W Curber...

  • Page 40: Operating The Machine

    Install both weights for curb installation and finishing. Depending on the consistency of the concrete, the operator may choose to remove one weight when per- forming curb-only installations. LBC-24W Curber 3-17...

  • Page 41: Transporting The Lbc-24W Curber

    Section 3 OPERATION TRANSPORTING THE LBC-24W CAUTION: Secure the machine with chains, cables, and binders of sufficient CURBER strength to prevent the machine from moving or breaking loose When transporting the machine on a flat bed vehi- during travel. cle, the vehicle must be capable of carrying the machine safely in all driving situations.

  • Page 42: Maintenance

    TORQUE HUBS ..............4-16 LBC-24W Curber...
  • Page 43 HYDRAULIC SCHEMATIC ............4-35 LBC-24W Curber...

  • Page 44: General Information

    ROUTINE MAINTENANCE This section gives the necessary procedures for rou- GENERAL INFORMATION tine and general maintenance on the LBC-24W Curber. Before starting any Maintenance program Maintenance must be a planned program that on the machine, it is important to READ, UNDER-...
  • Page 45 Engine Coolant Replace 50/50 Antifreeze Hydraulic Oil Replace AW32 Hydraulic Filter (Low Pressure) Replace 983835-01 Hydraulic Filter (High Pressure) Replace 983976-01 Hydraulic Strainer Replace 33148 Steering Bearings Re-Pack Wheel Bearing Grease Torque Hubs Check and Fill 50W Gear Lubricant LBC-24W Curber...
  • Page 46 1100 1990 1490 2380 1780 3230 2420 12 UNF 1670 1250 2270 1700 2710 2040 3680 2760 1-1/2 6 UNC 1950 1460 2640 1980 3160 2370 4290 3210 12 UNF 2190 1650 2970 2230 3560 2670 4820 3620 LBC-24W Curber...
  • Page 47 320.0 428.04 321.03 580.0 435.0 M24 x 3 516.12 409.59 740.0 555.0 754.38 557.19 1010.0 755.0 M27 x 3 797.04 597.78 1080.0 810.0 1084.86 811.80 1470.0 1100.0 M30 x 3.5 1084.86 811.80 1470.0 1100.0 1476.00 1107.00 2000.0 1500.0 LBC-24W Curber...

  • Page 48: Maintenance Schedule

    1. Check for loose, damaged, missing or corroded GENERAL INFORMATION parts. Repair or replace as required. Preventive maintenance on the LBC-24W Curber 2. Check for damaged, loose, or missing decals. will provide years of trouble-free operation. Replace decals as required.

  • Page 49: Engine Maintenance

    Wear eye protection when using compressed air for drying or cleaning components. Never point the nozzle at another individual. Use a safety reduction valve to reduce air pressure to a safe level. Compressed air can cause serious personal injury if misused. LBC-24W Curber...
  • Page 50 4. Install cap. 8. Pinch the vacuator valve together and remove dirt from the valve. 9. Install end cover and secure with spring clips. Make sure vacuator valve is located on the bot- tom of the end cover after installation. LBC-24W Curber...

  • Page 51: Radiator And Coolant System

    The Curber is filled with a 50/50 mixture of antifreeze and water at the factory with protection to -34ºF (-37ºC). Some geographical areas may require special antifreeze or coolant practices. Contact the local authorized dealer for additional information. 4-10 LBC-24W Curber...

  • Page 52: Battery Maintenance

    3. Always connect a booster battery in the proper post of battery. It is advisable to polarity [negative (-) to negative (-) and positive disconnect the negative (-) cable (+) to positive (+)]. first and connect it last. Reversed polarity can damage the electrical system. LBC-24W Curber 4-11...

  • Page 53: Electrical System

    13.5 volts. If CAUTION: Replace fuses and circuit breakers multimeter does not indicate minimum charge, with correct amperage to prevent check the machine charging system. damage from system overload. 4-12 LBC-24W Curber...
  • Page 54 TABLE 4-4. BLADE TYPE FUSE CODES NUMBER AMPERAGE RATING CIRCUIT Steering Switches Auger Lift, Hopper Lift Steering Computer Power Top-Con Power Front Wheel Alignment Rear Wheel Height Adjustment Auxiliary Part Main Power Glow Plug FIGURE 4-5. FUSE BLOCK LBC-24W Curber 4-13...

  • Page 55: Steering Calibration

    Both turn lights should go out indicating that the steering sensor is calibrated 2. Allow the engine to cool completely. in a straight position. 3. Locate the hydraulic filter on the right side of the Curber (Figure 4-7). FIGURE 4-6. STEERING CALIBRATION 4-14 LBC-24W Curber...
  • Page 56 AW32 as necessary. ter head-mounting surface. 13. Start engine and check for leaks. Tighten or 7. Drain and remove the filter element from the fil- replace filter as necessary. ter bowl. LBC-24W Curber 4-15...

  • Page 57: Tires And Wheels

    Wear eye protection and chemical rims, or missing wheel bolts or nuts. resistant gloves when using sol- The tires on the LBC-24W Curber are filled with sili- vent for cleaning purposes. Some cone. A plug (Figure 4-9) is inserted into the tire to solvents can cause skin irritation fill the hole used to fill the tires with silicone.

  • Page 58: Storage

    5. Remove the battery and store in a cool, dry refilled with LeeBoy approved place. fluid. Failure to do this could 6. Check air filter restriction gauge. Clean the air result in premature failure of the cleaner assembly and precleaner.

  • Page 59: Removing The Machine From Storage

    8. Smooth the decal into place with a sponge and check for air bubbles. Small air pockets may be pierced with a pin and smoothed out. When the decal is completely smoothed out, carefully remove the top paper. 4-18 LBC-24W Curber...

  • Page 60: Troubleshooting

    Clean or replace filter elements. dirt, snow, or water. Injection pump malfunctions. See your authorized dealer. Injection nozzle(s) malfunctions. See your authorized dealer. Worn piston rings or low See your authorized dealer. compression. Blown head gasket. See your authorized dealer. LBC-24W Curber 4-19...
  • Page 61 Injection pump or nozzle(s) mal- See your authorized dealer. functions. Basic engine malfunction. Refer to Kubota engine manual. Leaking head gasket, sticking or burnt valves, valve clearance or valve timing incorrect, or worn or broken piston rings. 4-20 LBC-24W Curber...
  • Page 62 Park brake dragging. Adjust linkage. Check park brake disc for warping or scoring. Check park brake cable for binding. Overheating of park brake disc indicates dragging. Repair or replace park brake disc and/or park brake cable as required. LBC-24W Curber 4-21...
  • Page 63 Incorrect grade of fuel used. Drain and flush fuel tank and refill with correct grade of fuel. Replace fuel filter. Injection pump or nozzle(s) See your authorized dealer. malfunctions. Basic engine malfunction: Refer to Kubota engine manual. excessive oil consumption. 4-22 LBC-24W Curber...
  • Page 64 Replace radiator shroud. Refer to damaged. Kubota engine manual. Engine overloaded. Reduce load. Operate in lower gear. Radiator cap not sealing. Replace radiator cap. Fan on backwards or damaged. Inspect and reinstall or replace fan. Refer to Kubota engine manual. LBC-24W Curber 4-23...
  • Page 65 Excessive Fuel Consumption. Air system restricted. Clean or replace air filter elements. Fuel system leakage. Refer to Kubota engine manual. Incorrect grade of fuel. Drain and flush fuel tank and refill with correct grade of fuel. Replace fuel filter. 4-24 LBC-24W Curber...
  • Page 66 Starter motor turns but will not Starter pinion gear not engaging Pinion shift mechanism jammed. crank engine. flywheel ring gear. Repair or replace starter motor. Pinion gear teeth broken. Repair or replace starter motor. Flywheel ring gear teeth broken. Replace ring gear. LBC-24W Curber 4-25...
  • Page 67 ON posi- tion. If 12 volts available, replace ignition switch. Excessive noise when cranking Broken teeth on flywheel ring gear Replace starter motor or ring gear. engine. or starter pinion gear. Major engine malfunction. See authorized dealer. 4-26 LBC-24W Curber...
  • Page 68 Drain, flush, and fill the hydraulic oil reservoir with the correct oil. Replace the oil filter. Transmission or hydraulic internal See your authorized dealer. leakage. Hydraulic system overheating due Check for clogged hydraulic oil to internal leakage. cooler. See your authorized dealer. LBC-24W Curber 4-27...
  • Page 69 Replace damaged hoses. Worn pump, loose pump drive cou- See your authorized dealer. pling, loose pump attaching hard- ware, leakage in hydraulic system (pump remains in stroke), or mis- alignment between pump and engine. 4-28 LBC-24W Curber...
  • Page 70 (battery hot or boiling). necessary. Noisy alternator. Alternator bearings. Remove alternator belt and turn alternator by hand. If pulley turns rough, repair or replace alternator. Worn drive belt. Check and replace belt. Internal alternator malfunction. Repair or replace alternator. LBC-24W Curber 4-29...

  • Page 71: Main Diagram, Positive Feeds/Engine

    Section 4 MAINTENANCE FIGURE 4-10. MAIN DIAGRAM, POSITIVE FEEDS/ENGINE LBC-24W Curber 4-31...
  • Page 72 Section 4 MAINTENANCE FIGURE 4-11. FRONT WHEEL HEIGHT, AUXILIARY 1 & 2, AUGER LIFT, AND HOPPER LIFT LBC-24W Curber 4-32...
  • Page 73 Section 4 MAINTENANCE FIGURE 4-12. PLUS 1 CONTROLS LBC-24W Curber 4-33...
  • Page 74 Section 4 MAINTENANCE FIGURE 4-13. TOPCON CONTROLS LBC-24W Curber 4-34...
  • Page 75 Section 4 MAINTENANCE FIGURE 4-14. HYDRAULIC SCHEMATIC LBC-24W Curber 4-35...
  • Page 76 ALPHABETICAL INDEX ............. .IPL-73 LBC-24W Curber...
  • Page 77 Designator Index is provided listing all equipment dash are not illustrated. designators listed in the Illustrated Parts List. (7) If a company other than Leeboy is referred to as the original manufacturer of some of the parts, these parts may carry the original manu- facturers part number or a Leeboy part number.
  • Page 78 Section 5 ILLUSTRATED PARTS LIST FIGURE 1. TOP ASSEMBLY IPL-4 LBC-24W Curber...
  • Page 79 ATTACHING PARTS 984080 *HINGE, MALE -----*----- 984190 *GROUP, FRAME (See Fig 9 for Breakdown) 983607 *KIT, DECAL, SAFETY/OPS 984600 *KIT, DECAL, LOGO 984199-08 *J-BOX, TOPCON 984199-06 *SENSOR, SLOPE, TOPCON 984199-03 *HARNESS, SLOPE SENSOR, TOPCON - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-5...
  • Page 80 Section 5 ILLUSTRATED PARTS LIST FIGURE 2. ELECTRICAL GROUP (1 OF 4) IPL-6 LBC-24W Curber...
  • Page 81 Section 5 ILLUSTRATED PARTS LIST TABLE 2. ELECTRICAL GROUP (1 OF 4) ITEM NO. PART NO. DESCRIPTION QTY. 987198 GROUP, ELECTRICAL, CURBER (See Fig 1 for NHA) 987335 *GROUP, CONTROL CONSOLE (See Fig 3 for Breakdown) ATTACHING PARTS 102-205-1A *CSHH, .375-16 X 1.00, GR5 118-3 *WASHER, LOCK, .375 116-3...
  • Page 82 Section 5 ILLUSTRATED PARTS LIST FIGURE 2. ELECTRICAL GROUP (2 OF 4) IPL-8 LBC-24W Curber...
  • Page 83 *WASHER, LOCK, .500 116-5 *NUT, HEX, .500-13 -----*----- -100 984200 *KIT, RS485 WAND SENSOR, TOPCON 984199-09 **SENSOR, ROTATING, STRING LINE 984199-10 **ARM, SENSOR, MOLD ATTACHING PARTS 118-5 *WASHER, LOCK, .500 116-5 *NUT, HEX, .500-13 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-9...
  • Page 84 Section 5 ILLUSTRATED PARTS LIST FIGURE 2. ELECTRICAL GROUP (3 OF 4) IPL-10 LBC-24W Curber...
  • Page 85 Section 5 ILLUSTRATED PARTS LIST TABLE 2. ELECTRICAL GROUP (3 OF 4) ITEM NO. PART NO. DESCRIPTION QTY. 983050 *COILED CORD, 6S16S 1.5 TO 7.5 FT. -150 985928 *GROUP, FRONT WHEEL SENSOR 987048 **BELT, GEAR, XL, 85 TOOTH 985916 **PULLEY, GEARBELT, STEERING ATTACHING PARTS 22025 *THD’D ROD, .312-18 X 2.50,GR5...
  • Page 86 Section 5 ILLUSTRATED PARTS LIST FIGURE 2. ELECTRICAL GROUP (4 OF 4) IPL-12 LBC-24W Curber...
  • Page 87 984663 *HARNESS, ENGINE, CURBER - See Section 4 for Schematic -420 984664 *HARNESS, PEDESTAL, CURBER - See Section 4 for Schematic -430 984685 *HARNESS, FUSE BLOCK, CURBER - See Section 4 for Schematic - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-13...
  • Page 88 Section 5 ILLUSTRATED PARTS LIST FIGURE 3. CONTROL CONSOLE (1 OF 3) IPL-14 LBC-24W Curber...
  • Page 89 GROUP, CONTROL CONSOLE, CURBER (See Fig 2 for NHA) 984722 *ACCESS PANEL, BOTTOM ATTACHING PARTS 102-05-1A *CSHH, .250-20 X 1.00 118-1 *WASHER, LOCK, .250 -----*----- 984723 *ACCESS PANEL REAR ATTACHING PARTS 102-05-1A *CSHH, .250-20 X 1.00 118-1 *WASHER, LOCK, .250 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-15...
  • Page 90 Section 5 ILLUSTRATED PARTS LIST FIGURE 3. CONTROL CONSOLE (2 OF 3) IPL-16 LBC-24W Curber...
  • Page 91 851391 *SWITCH, TOGGLE, SPST ATTACHING PARTS 119-5 *WASHER, FLAT, SAE, .500 987906 *NUT, TOGGLE SWITCH -----*----- 851392 *SWITCH, TOGGLE, 3-POS, SPDT ATTACHING PARTS 119-5 *WASHER, FLAT, SAE, .500 987906 *NUT, TOGGLE SWITCH -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-17...
  • Page 92 Section 5 ILLUSTRATED PARTS LIST FIGURE 3. CONTROL CONSOLE (3 OF 3) IPL-18 LBC-24W Curber...
  • Page 93 *NUT, TOGGLE SWITCH -----*----- 72055 *KNOB, 0.25 SHAFT, POTENTIOMETER 72857 *POTENTIOMETER, 50 OHM, 25 WATT ATTACHING PARTS 987906 *NUT, TOGGLE SWITCH -----*----- 851390 *SWITCH, TOGGLE, DPDT ATTACHING PARTS 987906 *NUT, TOGGLE SWITCH -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-19...
  • Page 94 *SWITCH, EMERGENCY STOP (Includes 981510) 981510 *KNOB, EMERGENCY SWITCH 984145 *SWITCH, IGNITION -300 985385 *DECAL, CURBER PANEL, BOTTOM -310 985386 *DECAL, CURBER PANEL, TOP 987308 *CONTROL PANEL, CURBER 984145-01 KEY, FOR SWITCH, IGNITION - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-21...
  • Page 95 Section 5 ILLUSTRATED PARTS LIST FIGURE 4. HYDRAULIC GROUP (1 OF 3) IPL-22 LBC-24W Curber...
  • Page 96 *CSHH, 1.00-8 X 8.00, GR5 102-921-1A *CSHH, 1.00-8 X 5.00, GR5 -----*----- 985351 *CYLINDER, HYDRAULIC, 2.50 X 8.00 X 1.125 ROD ATTACHING PARTS 81184 *CSHH, 1.00-8 X 8.00, GR5 102-921-1A *CSHH, 1.00-8 X 5.00, GR5 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-23...
  • Page 97 Section 5 ILLUSTRATED PARTS LIST FIGURE 4. HYDRAULIC GROUP (2 OF 3) IPL-24 LBC-24W Curber...
  • Page 98 TABLE 4. HYDRAULIC GROUP (2 OF 3) ITEM NO. PART NO. DESCRIPTION QTY. 870091 *CYLINDER, HYDRAULIC, 2.50 X 12.00 X 1.125 ROD *ATTACHING PARTS 210060 *PIN, CLEVIS, 1.00 X 2.625 W/1.5 HD 80336 *PIN, COTTER, .188 X 1.50 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-25...
  • Page 99 Section 5 ILLUSTRATED PARTS LIST FIGURE 4. HYDRAULIC GROUP (3 OF 3) IPL-26 LBC-24W Curber...
  • Page 100 -----*----- 987330 *PLATE, REAR MANIFOLD ATTACHING PARTS 102-305-1A *CSHH, .375-16 X 1.00, GR5 118-3 *WASHER, LOCK, .375 -----*----- -310 987088 *VIBRATOR, HYD, STR (See Fig 8 for Breakdown) -320 987199 *KIT, FITT/HOSE, CURBER - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-27...
  • Page 101 Section 5 ILLUSTRATED PARTS LIST FIGURE 5. VALVE ASSEMBLY IPL-28 LBC-24W Curber...
  • Page 102 *ELEMENT, LOGIC, N.O. 984656-03 *FLOW DIVIDER/COMBINER 984656-01 *VALVE BODY -140 984656-15 *PLUG, SAE02 -150 984656-16 *PLUG, SAE06 -160 984656-17 *PLUG, SAE04 -170 984656-19 *PLUG, MB700-070 -180 984656-20 *ORIFICE, REMOVABLE -190 984656-21 *PLUG, 5MM EXPANSION - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-29...
  • Page 103 Section 5 ILLUSTRATED PARTS LIST FIGURE 6. VALVE ASSEMBLY, REAR MANIFOLD IPL-30 LBC-24W Curber...
  • Page 104 984657-04 *CONTROL, FLOW, NORM CLOSED PROP 984657-15 **NUT, HEX, SOLENOID COIL 984657-06 **COIL, 12 VDC DEUTSCH 984657-02 *VLV, COUNTERBALANCE 984657-03 *VLV, NEEDLE 984657-01 *VALVE BODY -140 984657-12 *PLUG, SAE06 -150 984657-13 *PLUG, SAE02 - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-31...
  • Page 105 Section 5 ILLUSTRATED PARTS LIST FIGURE 7. MOLD GROUP IPL-32 LBC-24W Curber...
  • Page 106 *NUT, HEX, .375-24 118-3 *WASHER, LOCK, .375 119-3 *WASHER, FLAT, SAE, .375 -----*----- 987413 SLIDE, MOLD BACK ATTACHING PARTS 115-3 *NUT, HEX, .375-24 118-3 *WASHER, LOCK, .375 119-3 *WASHER, FLAT, SAE, .375 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-33...
  • Page 107 Section 5 ILLUSTRATED PARTS LIST FIGURE 8. COVER GROUP IPL-34 LBC-24W Curber...
  • Page 108 -170 987369 *GROUP, SENSOR ARM COVER 985932 **FRONT, STRINGLINE SENSOR, MOUNTING ARM 984740 **LOCK, ARM, W/M 987509 **CONNECT SENSOR, W/M 984740 **LOCK, ARM, W/M 987370 **ARM1, SENSOR COVER, W/M 983703 *TOP, COVER/CHUTE, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-35...
  • Page 109 Section 5 ILLUSTRATED PARTS LIST FIGURE 9. FRAME ASSEMBLY IPL-36 LBC-24W Curber...
  • Page 110 GROUP, AUGER (See Fig 19 for Breakdown) 985370 GROUP, SENSOR ARM (See Fig 20 for Breakdown) GROUP, CONTROL PEDESTAL & TOW RING (See Fig 21 for Breakdown) GROUP, ACCESS DOOR AND COVER (See Fig 22 for Breakdown) - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-37...
  • Page 111 Section 5 ILLUSTRATED PARTS LIST FIGURE 10. LEFT AND RIGHT WHEEL LIFT GROUP IPL-38 LBC-24W Curber...
  • Page 112 *WHEEL LIFT, RIGHT REAR, W/M 983820 GROUP, WHEEL LIFT, LEFT REAR (See Fig 9 for NHA) 983872 *WEAR PLATE, REAR WHEEL LIFT ATTACHING PARTS 81238 *CSFHS, .250-20 X 1.00 -----*----- 983886 *WHEEL LIFT, LEFT REAR, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-39...
  • Page 113 Section 5 ILLUSTRATED PARTS LIST FIGURE 11. WHEEL LIFT, FRONT IPL-40 LBC-24W Curber...
  • Page 114 *STEERING PIN, FRONT WHEEL LIFT 129-413 *KEYSTOCK, SQ, 0.500 X 2.00 -120 300109 *HOUSING, YOKE SHAFT 983891 *WEAR PLATE, FRONT WHEEL LIFT ATTACHING PARTS 102-7-1A *CSHH, .250-20 X 1.50,GR5 -----*----- 983895 *WHEEL LIFT, FRONT - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-41...
  • Page 115 Section 5 ILLUSTRATED PARTS LIST FIGURE 12. LEFT REAR TIRE, WHEEL & TORQUE HUB IPL-42 LBC-24W Curber...
  • Page 116 *TORQUE HUB, 6.09:1, COMER ATTACHING PARTS 80990 *CSHH, M10-1.50 X 35MM 118-M10 *WASHER, LOCK, 10MM 80474 *WASHER, FLAT, M10 -----*----- 984753 *SEAL, O-RING 984732 *PLATE, SPACER, TORQUE HUB 984753 *SEAL, O-RING 985382 *MOTOR, HYD, DRIVE, CURBER - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-43...
  • Page 117 Section 5 ILLUSTRATED PARTS LIST FIGURE 13. RIGHT REAR TIRE & WHEEL & TORQUE HUB IPL-44 LBC-24W Curber...
  • Page 118 *TORQUE HUB, 6.09:1, COMER ATTACHING PARTS 80990 *CSHH, M10-1.50 X 35MM 118-M10 *WASHER, LOCK, 10MM 80474 *WASHER, FLAT, M10 -----*----- 984753 *SEAL, O-RING 984732 *PLATE, SPACER, TORQUE HUB 984753 *SEAL, O-RING 985382 *MOTOR, HYD, DRIVE, CURBER - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-45...
  • Page 119 Section 5 ILLUSTRATED PARTS LIST FIGURE 14. FRONT TIRE, WHEEL & TORQUE HUB IPL-46 LBC-24W Curber...
  • Page 120 *TORQUE HUB, 6.09:1, COMER ATTACHING PARTS 80990 *CSHH, M10-1.50 X 35MM 118-M10 *WASHER, LOCK, 10MM 80474 *WASHER, FLAT, M10 -----*----- 984753 *SEAL, O-RING 984732 *PLATE, SPACER, TORQUE HUB 984753 *SEAL, O-RING 985382 *MOTOR, HYD, DRIVE, CURBER - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-47...
  • Page 121 Section 5 ILLUSTRATED PARTS LIST FIGURE 15. ENGINE & FUEL FILTER (1 OF 2) IPL-48 LBC-24W Curber...
  • Page 122 -----*----- 700530 **MUFFLER, 635B W/LOMBARDINI 36573 **CLAMP, AIR CLEANER MOUNT, 6"ID ATTACHING PARTS 100-203-1A **CSHH, .375-24 X .75, GR5 119-3 **WASHER, FLAT, .375 143-3 **NUT, LOCK, .375 -----*----- 987442 **MUFFLER BRACKET, CURBER, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-49...
  • Page 123 -----*----- 986775-14 **ENGINE MOUNT ATTACHING PARTS 102-105-1A *CSHH, .312-18 X 1.00, GR5 119-2 *WASHER, FLAT, .312 -----*----- 38845-1 **FILTER ELEMENT, FUEL (Filter Only) 100-205-1A *CSHH, .375-24 X 1.00, GR5 115-3 *NUT, HEX, .375-24 - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-51...
  • Page 124 Section 5 ILLUSTRATED PARTS LIST FIGURE 15. ENGINE & FUEL FILTER (2 OF 2) IPL-52 LBC-24W Curber...
  • Page 125 986775-10 **BASE, ELECTRIC ACTUATOR ATTACHING PARTS 81132 *CSHH, M10-1.25 X 25 MM 118-M10 *WASHER, LOCK, 10MM 102-107-1A *CSHH, .312-18 X 1.50, GR5 81283 *WASHER, .313 x 1.25, SS 143-2 *NUT, LOCK, .312-18 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-53...
  • Page 126 Section 5 ILLUSTRATED PARTS LIST FIGURE 16. ENGINE COOLING SYSTEM IPL-54 LBC-24W Curber...
  • Page 127 986775-02 *HOSE, RADIATOR, LOWER, KUBOTA 986775-01 *HOSE, RADIATOR, UPPER, KUBOTA 986775-03 *PRESSURE CAP, RADIATOR , KUBOTA 984802 *RADIATOR 984807 *GUARD, RADIATOR 984816 *SHROUD, FAN 984818 *GUARD, FAN -150 986775-15 *BELT, FAN, KUBOTA ENGINE - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-55...
  • Page 128 Section 5 ILLUSTRATED PARTS LIST FIGURE 17. FUEL TANK IPL-56 LBC-24W Curber...
  • Page 129 983817 *FUEL TANK, W/M ATTACHING PARTS 102-205-1A *CSHH, .375-16 X 1.00, GR5 119-3 *WASHER, FLAT, SAE, .375 102-205-1A *CSHH, .375-16 X 1.25, GR5 119-3 *WASHER, FLAT, SAE, .375 116-3 *NUT, HEX, .375-16 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-57...
  • Page 130 Section 5 ILLUSTRATED PARTS LIST FIGURE 18. HYDRAULIC TANK IPL-58 LBC-24W Curber...
  • Page 131 *GAUGE, SIGHT LEVEL/TEMP, HYD OIL ATTACHING PARTS 102-407-1A *CSHH, .500-13 X 1.50, GR5 -----*----- 983818 *HYDRAULIC TANK ATTACHING PARTS 102-211-1A *CSHH, .375-16 X 2.50 119-3 *WASHER, FLAT, SAE, .375 116-3 *NUT, HEX, .375-16 - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-59...
  • Page 132 Section 5 ILLUSTRATED PARTS LIST FIGURE 19. AUGER IPL-60 LBC-24W Curber...
  • Page 133 *NUT, HEX, .500-13 -----*----- -130 987395 *GROUP, AUGERS & SHAFT, CURBER 860110C **AUGER SECTION LH CASTED YELLOW ATTACHING PARTS 102-615-1A **CSHH, .625-11 X 3.50, GR5 119-7 **WASHER, FLAT, SAE, .625 116-7 **NUT, HEX, .625-11 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-61...
  • Page 134 PART NO. DESCRIPTION QTY. 987333 **AUGER, 9"ODX14"LG ATTACHING PARTS 102-615-1A **CSHH, .625-11 X 3.50, GR5 119-7 **WASHER, FLAT, SAE, .625 116-7 **NUT, HEX, .625-11 -----*----- 987357 **CUTTER, AUGER, W/M 985317 *BLADE, AUGER, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-63...
  • Page 135 Section 5 ILLUSTRATED PARTS LIST FIGURE 20. SENSOR ARM IPL-64 LBC-24W Curber...
  • Page 136 102-421-1 *CSHH, .500-13 X 5.00, GR5 119-5 *WASHER, FLAT, SAE, .500 143-5 *NUT, LOCK, .500-13 -----*----- 985371 *STATIONARY ARM, W/M ATTACHING PARTS 102-405-1A *CSHH, .500-13 X 1.00, GR5 118-5 *WASHER, LOCK, .500 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-65...
  • Page 137 Section 5 ILLUSTRATED PARTS LIST FIGURE 21. CONTROL PEDESTAL & TOW RING IPL-66 LBC-24W Curber...
  • Page 138 BOLT, 3/8" X 1 HEX (Part of Frame Grp) -----*----- 984065 SWITCH, LIMIT (Part of Electrical Grp) 984837 HARNESS, FT WHEEL, HT (Part of Electrical Grp) 81079 MACH SCREW, PH, #10-24 X 2.50 80824 NUT, HEX, #10-24 -----*----- - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-67...
  • Page 139 Section 5 ILLUSTRATED PARTS LIST FIGURE 22. ACCESS DOOR & COVER (1 OF 2) IPL-68 LBC-24W Curber...
  • Page 140 GROUP, ACCESS DOOR AND COVER (See Fig 9 for NHA) 985900 INST, GRILL LIGHT & HIGH FLOW ATTACHING PARTS 102-203-1A *CSHH, .375-16 X .75, GR5 118-3 *WASHER, LOCK, .375 119-3 *WASHER, FLAT, SAE, .375 -----*----- 984827 *GRILLE 984184 FRAME, CURBER, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-69...
  • Page 141 Section 5 ILLUSTRATED PARTS LIST FIGURE 22. ACCESS DOOR & COVER (2 OF 2) IPL-70 LBC-24W Curber...
  • Page 142 983830 ACCESS COVER, W/M ATTACHING PARTS 102-205-1A *CSHH, .375-16 X 1.00, GR5 118-3 *WASHER, LOCK, .375 119-3 *WASHER, FLAT, SAE, .375 -----*----- 985394 SAFETY TUBE 985384 **PIN, QUICK RELEASE 984184 FRAME, CURBER, W/M - ITEM NOT ILLUSTRATED LBC-24W Curber IPL-71...
  • Page 143 984117 BRASS HOSE BARB, 5/16 I.D. 983894 BUSHING, TAPER, FRONT WHEEL LIFT 330010 CAP, FUEL, W/GAUGE 140030HL CAP, HYD OIL TANK (LOCKABLE) 36573 CLAMP, AIR CLEANER MOUNT, 6” ID 71172 CLAMP, MUFFLER, 2” 71172 CLAMP, MUFFLER, 2” LBC-24W Curber IPL-73...
  • Page 144 CSHH, .375-16 X 1.00, GR5 102-205-1A CSHH, .375-16 X 1.00, GR5 102-205-1A CSHH, .375-16 X 1.00, GR5 102-205-1A CSHH, .375-16 X 1.00, GR5 102-206-1A CSHH, .375-16 X 1.25, GR5 102-211-1A CSHH, .375-16 X 2.50, GR5 100-203-1A CSHH, .375-24 X .75, GR5 IPL-74 LBC-24W Curber...
  • Page 145 985351 CYLINDER, HYDRAULIC, 2.50 X 8.00 X 1.125 ROD 984656-11 D05 PROPORTIONAL DCV 985385 DECAL, CURBER PANEL, BOTTOM 985386 DECAL, CURBER PANEL, TOP 984656-23 DECAL, CURBER, HYD DRIVE 984657-14 DECAL, VLV, CURBER ACCESSORY 986775-13 DIPSTICK, KUBOTA CURBER LBC-24W Curber IPL-75...
  • Page 146 GAUGE, SIGHT LEVEL/TEMP, HYD OIL 984827 GRILLE 987409 GROUP, ATTACH ARM GROUP, ACCESS DOOR AND COVER GROUP, ACCESS DOOR AND COVER 985319 GROUP, AUGER 985319 GROUP, AUGER 987395 GROUP, AUGERS & SHAFT, CURBER 987335 GROUP, CONTROL CONSOLE IPL-76 LBC-24W Curber...
  • Page 147 GROUP, WHEEL LIFT, FRONT 983820 GROUP, WHEEL LIFT, LEFT REAR 983820 GROUP, WHEEL LIFT, LEFT REAR 983819 GROUP, WHEEL LIFT, RIGHT REAR 37, 39 986775-12 GRP, ELEC THROTTLE, ARM/BASE 986775-12 GRP, ELECTRICAL THROTTLE, ARM/BASE 984818 GUARD, FAN 984807 GUARD, RADIATOR LBC-24W Curber IPL-77...
  • Page 148 LEFT REAR TIRE, WHEEL AND TORQUE HUB 985318 LEG AUGER, W/M 31986 LIGHT, BLUE, DASH 31985 LIGHT, GREEN, DASH 17, 19 984740 LOCK, ARM, W/M 984740 LOCK, ARM, W/M 984740 LOCK, ARM, W/M 984740 LOCK, ARM, W/M IPL-78 LBC-24W Curber...
  • Page 149 NUT, HEX, .500-13 116-5 NUT, HEX, .500-13 116-7 NUT, HEX, .625-11 116-7 NUT, HEX, .625-11 116-7 NUT, HEX, .625-11 116-8 NUT, HEX, .750-10 984656-28 NUT, HEX, COIL ZL70 80453 NUT, HEX, M06-1.00 984657-15 NUT, HEX, SOLENOID COIL 29, 31 LBC-24W Curber IPL-79...
  • Page 150 PIVOT ARM, W/M 987330 PLATE, REAR MANIFOLD 984732 PLATE, SPACER, TORQUE HUB 43, 45, 47 984656-21 PLUG, 5MM EXPANSION 984656-19 PLUG, MB700-070 984656-15 PLUG, SAE02 984657-13 PLUG, SAE02 984656-17 PLUG, SAE04 984656-17 PLUG, SAE04 984657-12 PLUG, SAE06 IPL-80 LBC-24W Curber...
  • Page 151 STRAINER, SUCTION 981507 SWITCH, EMERGENCY STOP 984145 SWITCH, IGNITION 984065 SWITCH, LIMIT 851392 SWITCH, TOGGLE, 3-POS, SPDT 17, 19 72086 SWITCH, TOGGLE, DPDT 851390 SWITCH, TOGGLE, DPDT 37521 SWITCH, TOGGLE, DPDT, 3-POS 851391 SWITCH, TOGGLE, SPST 17, 19 LBC-24W Curber IPL-81...
  • Page 152 43, 45, 47 119-1 WASHER, FLAT, SAE, .250 119-2 WASHER, FLAT, SAE, .312 119-2 WASHER, FLAT, SAE, .312 119-2 WASHER, FLAT, SAE, .312 119-3 WASHER, FLAT, SAE, .375 119-3 WASHER, FLAT, SAE, .375 119-3 WASHER, FLAT, SAE, .375 IPL-82 LBC-24W Curber...
  • Page 153 WASHER, LOCK, .500 118-5 WASHER, LOCK, .500 118-5 WASHER, LOCK, .500 61, 65 118-5 WASHER, LOCK, .500 9, 67 118-5 WASHER, LOCK, .500 118-6 WASHER, LOCK, .562 118-7 WASHER, LOCK, .625 118-M10 WASHER, LOCK, 10MM 43, 45, 47 LBC-24W Curber IPL-83...
  • Page 154 WASHER, VIBRATION ISOLATOR 983891 WEAR PLATE, FRONT WHEEL LIFT 983872 WEAR PLATE, REAR WHEEL LIFT 983872 WEAR PLATE, REAR WHEEL LIFT 983895 WHEEL LIFT, FRONT 983886 WHEEL LIFT, LEFT REAR, W/M 983875 WHEEL LIFT, RIGHT REAR, W/M IPL-84 LBC-24W Curber...
  • Page 155 Sauer-Danfoss US Company All Products Warranty Policies and Procedures...
  • Page 156 Sauer-Danfoss (US) Company All Product Warranty Policies and Procedures WARRANTY Sauer-Danfoss (US) Company ("Sauer-Danfoss") warrants for the applicable Warranty Period referred to below to the original equipment manufacturer or authorized distributor purchasing a Sauer-Danfoss Product (“Buyer”) that the product will be free from defects in material and workmanship at the time of shipment from Sauer-Danfoss, and will conform to the drawings and specifi...
  • Page 157 Sauer-Danfoss (US) Company All Product Warranty Policies and Procedures WARRANTY PERIODS New products The Warranty Period is limited to the earlier of: (i) 24 consecutive months (2 years) from the date of fi rst use of the product, or (ii) 36 consecutive months (3 years) from the date of original shipment of the product from Sauer- Danfoss.
  • Page 158 OUR PRODUCTS Sauer-Danfoss Hydraulic Power Systems – Market Leaders Worldwide Hydrostatic transmissions Sauer-Danfoss is a comprehensive supplier providing complete Hydraulic power steering systems to the global mobile market. Electric power steering Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many Closed and open circuit axial piston others.
  • Page 159 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Displacement Piston Swashplate Piston Tapered Roller Tapered Roller Bearing Bearing Shaft Seal Valve Plate Cylinder Block Kit...
  • Page 160 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Contents INTRODUCTION Using this manual ................................4 Safety precautions ................................4 Unintended machine movement.......................... 4 Flammable cleaning solvents ..........................4 Fluid under pressure ..............................4 Personal safety ................................4 Symbols used in Sauer-Danfoss literature........................
  • Page 161 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Contents PRESSURE Port locations and gauge installation........................14 MEASUREMENT Required tools ..................................14 Gauge and port information........................14 Gauge port locations, radial ported units ....................14 Gauge port locations, axial ported units ....................14 INITIAL START-UP General....................................15 PROCEDURES...

  • Page 162: Introduction

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction USING THIS MANUAL This manual includes information for the normal operation, maintenance, and service of the Series 45 frame K and L open circuit pumps.The manual includes a description of the units and their individual components, troubleshooting information, adjustment instructions and minor repair procedures.

  • Page 163: Symbols Used In Sauer-Danfoss Literature

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction   SYMBOLS USED IN WARNING may result in injury Tip, helpful suggestion SAUER-DANFOSS   LITERATURE CAUTION may result in damage to Lubricate with hydraulic fluid product or property ...

  • Page 164: General Description

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction GENERAL DESCRIPTION Sauer-Danfoss Series 45 K and L frame open circuit piston pumps convert input torque into hydraulic power. Rotational force is transmitted through the input shaft to the cylinder block.The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block .

  • Page 165: The System Circuit

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction THE SYSTEM CIRCUIT The pump receives fluid directly from the reservoir through the inlet line. A screen placed in the inlet protects the pump from large contaminants.The output of the pump is directed to a PVG-32 multi-section load sensing directional control valve which directs fluid to the actuators in the system.

  • Page 166: Technical Specifications

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Technical specifications GENERAL SPECIFICATIONS Type of mounting SAE-B mounting flange. Auxiliary mounting pad options SAE-A, SAE-B, or SAE-B-B Control options Pressure Compensator Load Sensing (with PC) Port options Inlet and system ports: SAE flanged ports, code 61 or O-ring boss ports.

  • Page 167: Hydraulic Parameters

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Technical specifications HYDRAULIC Inlet pressure PARAMETERS Minimum pressure, continuous = 0.8 bar absolute [23.2 in Hg] (at reduced maximum pump speed) Minimum pressure, cold start = 0.5 bar absolute [14.8 in Hg] Pressure compensator valve setting Minimum: 100 bar [1450 psi] Maximum: 260 bar [3770 psi]...

  • Page 168: Auxiliary Mounting Pads

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features DISPLACEMENT LIMITER Frame K and L Series 45 pumps are Displacement limiter available with an optional maximum displacement limiter. If installed, this longer servo piston will limit the maximum displacement to 92%.

  • Page 169: Control Options

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features CONTROL OPTIONS The Series 45 Frames K and L have two possible control options, a Load Sensing (LS) control with Pressure Compensator (PC) or a PC only control. Operation Cross-section pump General...

  • Page 170: Cross-Section Ls Control

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features CONTROL OPTIONS LS control Typical load-sensing control valve (continued) The LS control is designed to match Load Return pressure pressure pump flow with system demand.The flow demand of the system is sensed by Tank the LS control as a pressure drop across the External Control Valve (ECV).

  • Page 171: Pressure Measurement

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Pressure measurement REQUIRED TOOLS The service procedures described in this manual can be performed using common mechanic’s hand tools. Special tools, if required are shown. Calibrate pressure gauges frequently to ensure accuracy.

  • Page 172: Initial Start-Up Procedures

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Initial start-up procedures GENERAL Follow this procedure when starting-up a new Series 45 installation or when restarting an installation in which the pump has been removed. WARNING Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.

  • Page 173: Fluid And Filter Maintenance

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Fluid and filter maintenance RECOMMENDATIONS To ensure optimum life of Series 45 products, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure.Take care to maintain fluid cleanliness when servicing.

  • Page 174: Troubleshooting Excessive Noise And / Or Vibration

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Troubleshooting EXCESSIVE NOISE AND / OR VIBRATION c i f i l u l l i . r i l l i . l e t i v , y s r i a t t i...

  • Page 175: System Operating Hot

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Troubleshooting SYSTEM OPERATING HOT c i f c i l l i F y f i . r i l l i n i l . r i c i f r i a r i a...

  • Page 176: Pressure Or Flow Instability

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Troubleshooting PRESSURE OR FLOW INSTABILITY (continued) i l i . y t s u j n i l l l i n i l e i l c i f l a i f e i...

  • Page 177: Pc Control Adjustment

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Adjustments PC CONTROL PC setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston PumpsTechnical Information Manual, BLN-10128, for more information. ...

  • Page 178: Ls Control Adjustment

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Adjustments LS CONTROL The LS setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual, BLN-10128, for more information. ...

  • Page 179: Minor Repair

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair SHAFT SEAL A lip type shaft seal is used in the Series 45 open circuit variable pumps.This seal can be REPLACEMENT replaced without major disassembly of the unit. Replacement of the shaft seal requires removal of the pump from the machine.

  • Page 180: Auxiliary Pads

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair AUXILIARY PADS Auxiliary mounting pads may be installed on pumps equipped with through-drive radial ported endcaps. Follow these steps to either remove, replace, or exchange auxiliary mounting pads.

  • Page 181: Control

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair CONTROL Disassembly 1. Remove the four screws (C300) Control assembly holding the control housing onto the  C118 end cap.   C138  C117 ...

  • Page 182: Reassembly

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair CONTROL Reassembly (continued) 13. Install the PC spool, spherical end Control assembly first, into the PC bore.The PC spool is  C118 the shorter of the two. Using a new ...

  • Page 183: Plug And Fitting Sizes And Torques

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair PLUG AND FITTING SIZES If any plugs or fittings are removed from the unit during service, install and torque AND TORQUES as indicated here.This drawing is a composite.Your configuration may differ but the appropriate wrench size and torque can be found here.
  • Page 184 OUR PRODUCTS Sauer-Danfoss Hydraulic Power Systems Hydrostatic transmissions – Market Leaders Worldwide Hydraulic power steering Sauer-Danfoss is a comprehensive supplier providing complete Electric power steering systems to the global mobile market. Closed and open circuit axial piston Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many pumps and motors others.
  • Page 214 ACX104C Potentiometer Rotary Position Sensor BLN-95-8939-8 Issued: January 1995 DESCRIPTION The ACX104C Potentiometer Rotary Position Sensor is designed for use as a steering feedback sensor on mobile equipment with automatic steering control systems. The ACX104C follows steering action of the wheels or tracks through rotation of its input shaft.
  • Page 215 ORDERING INFORMATION (continued) ORDER NUMBER APPLICATION OHMS POTENTIOMETER MOUNT CONNECTOR ACX104C1001 Steering Fdbk 1K, 20K 312°, 312° Flange 6 Pin MS ACX104C1100 Position Fdbk 312° Flange 6 Pin MS ACX104C1118 Angular Position 342° Flange Coil Cord ACX104C1126 Steering Fdbk 90° Flange 6 Pin MS ACX104C1134...
  • Page 216 DIMENSIONS 278B 1798 Dimensions of the ACX104C in Millimeters (Inches). BLN-95-8939-8...
  • Page 217 DIMENSIONS (continued) 1799 Dimensions of the ACX104C in Millimeters (Inches). THEORY OF OPERATION INSTALLATION The ACX104C Potentiometer Rotary Position Sensor pro- MOUNTING vides steering angle position information in automatic steering control systems, with a typical example shown in the Two mounting styles are available. If the mounting stud is Block Diagram.
  • Page 218 CONNECTION DIAGRAM 20K OHM 1K OHM 1K OHM 1 WATT 1K OHM 1K OHM 2.25 WATT ACX104C1068 ACX104C1100 ACX104C1118 ACX104C1001 1K OHM 50 OHM 1K OHM 1K OHM 25 WATTS ACX104C1152 ACX104C1134 ACX104C1167 ACX104C1191 25K OHM 2.25 WATTS 100K 1K OHM 20K OHM 1K OHM 1/2W...
  • Page 219 CUSTOMER SERVICE NORTH AMERICA EUROPE ORDER FROM ORDER FROM Sauer-Danfoss (US) Company Sauer-Danfoss (Neumünster) GmbH & Co. Customer Service Department Order Entry Department 3500 Annapolis Lane North Krokamp 35 Minneapolis, Minnesota 55447 Postfach 2460 Phone: (763) 509-2084 D-24531 Neumünster Fax: (763) 559-0108 Germany Phone: 49-4321-8710 DEVICE REPAIR...
  • Page 220 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 DESCRIPTION The System Five Control Box is a dual-function, machine control platform featuring the latest operator interface and proportional valve control technologies. The System Five Platform is capable of hosting a wide range of application-specific software.
  • Page 221 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 SPECIFICATIONS ELECTRICAL SUPPLY VOLTAGE 10-30V DC SUPPLY CURRENT Typical operating current 10.5A Maximum operating current EMISSIONS Applicable regulation: EN55022:1994 30-230MHz 40.0dB (mV/m) Max at 10m 230-1000MHz 47.0dB (mV/m) Max at 10m IMMUNITY...
  • Page 222 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 CONNECTORS Application specific MIL-C-5015 cylindrical connectors Gold Plated Contacts Conductive anticorrosive coating ENVIRONMENTAL OPERATING TEMPERATURE C to 60 MOISTURE Mil Std 810D, method 506 95% humidity at 60 soak SHOCK 50G 6 axis 1/2 sine 11ms...
  • Page 223 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 SERVICE PARTS FOR PART NUMBERS: 9164-0002 -0003 TOPCON Positioning Systems, Inc. 7400 National Drive • Livermore, CA • 94551 © Copyright 2004 Topcon Positioning Systems Inc. Page 4 OF 9 Specifications subject to change without notice...
  • Page 224 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 CONNECTOR PINOUTS FOR PART NUMBERS: 9164-0002 -0003 ) t f ) t f ) t f ) t f TOPCON Positioning Systems, Inc. 7400 National Drive • Livermore, CA • 94551 ©...
  • Page 225 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 SERVICE PARTS FOR PART NUMBERS: 9164-0001 -0004 TOPCON Positioning Systems, Inc. 7400 National Drive • Livermore, CA • 94551 © Copyright 2004 Topcon Positioning Systems Inc. Page 6 OF 9 Specifications subject to change without notice...
  • Page 226 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 CONNECTOR PINOUTS FOR PART NUMBERS: 9164-0001 -0004 o i t ( ) l o i t ( ) l ) t f ) t f ) t f ) t f ) t f ) t f...
  • Page 227 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 TYPICAL MOUNTING DETAIL TOPCON Positioning Systems, Inc. 7400 National Drive • Livermore, CA • 94551 © Copyright 2004 Topcon Positioning Systems Inc. Page 8 OF 9 Specifications subject to change without notice...
  • Page 228 Technical Data Sheet SYSTEM FIVE 9164 CONTROL BOX Doc. #7011-0104 Rev. C ECO #2220 ENVELOPE DIMENSIONS TOPCON Positioning Systems, Inc. 7400 National Drive • Livermore, CA • 94551 © Copyright 2004 Topcon Positioning Systems Inc. Page 9 OF 9 Specifications subject to change without notice...
  • Page 229 Technical Data Sheet SYSTEM FOUR PLUS SLOPE SENSOR 9150P/9152P Doc. #7011-0105 Rev. B ECO #2472 DESCRIPTION The 9150P\9152P slope sensor allows for precise measurement of cross slope whenever needed by a System Four or System Five application. The sensor follows the System Four RS-485 communication protocol developed by Topcon to provide the first digital communication system available for construction machine...
  • Page 230 Technical Data Sheet SYSTEM FOUR PLUS SLOPE SENSOR 9150P/9152P Doc. #7011-0105 Rev. B ECO #2472 SPECIFICATIONS ELECTRICAL RESOLUTION +/- 0.025% slope RANGE 9150P +/- 0-20% slope 9152P +/- 0-100% slope SUPPLY VOLTAGE 10-30 VDC SUPPLY CURRENT 200mA Typical operating current EMISSIONS Applicable regulation: EN55022:1994 30-230MHz...
  • Page 231 Technical Data Sheet SYSTEM FOUR PLUS SLOPE SENSOR 9150P/9152P Doc. #7011-0105 Rev. B ECO #2472 SERVICE PARTS STANDARD VIAL ORIENTATION TOPCON Positioning Systems, Inc. 7400 National Drive Livermore, CA 94551 (925) 245-8300 FAX (925) 245-8583 © Copyright 2005 Topcon Positioning Systems Inc. Page 3 OF 5 Specifications subject to change without notice...
  • Page 232 Technical Data Sheet SYSTEM FOUR PLUS SLOPE SENSOR 9150P/9152P Doc. #7011-0105 Rev. B ECO #2472 CONNECTOR PINOUTS TOPCON Positioning Systems, Inc. 7400 National Drive Livermore, CA 94551 (925) 245-8300 FAX (925) 245-8583 © Copyright 2005 Topcon Positioning Systems Inc. Page 4 OF 5 Specifications subject to change without notice...
  • Page 233 Technical Data Sheet SYSTEM FOUR PLUS SLOPE SENSOR 9150P/9152P Doc. #7011-0105 Rev. B ECO #2472 ENVELOPE DIMENSIONS TOPCON Positioning Systems, Inc. 7400 National Drive Livermore, CA 94551 (925) 245-8300 FAX (925) 245-8583 © Copyright 2005 Topcon Positioning Systems Inc. Page 5 OF 5 Specifications subject to change without notice...

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