Hydraulic Fluid Leak Detector Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Allow the engine to cool.

5. Disconnect the battery; refer to your machine Operator’s Manual.

Parts needed for this procedure:

1. Remove the hex-head screws that secure the console arm cover and remove the cover.

   Note: Save the screws for securing the console arm cover later.

2. Route the wire harness by positioning the light indicator and alarm leads in the console arm, following the main wire harness under the seat to the other side of the machine, and then behind the seat along the left-hand rail, so that the oil level sensor and solenoid valve leads are near the main hydraulic tank (diesel model only).

   Refer to Figure 1 for an overview of the wire-harness position and the connector locations.

   

   Figure 1

   Several parts removed from the machine for clarity.

   1. Indicator light connector
   2. Audio alarm connector
   3. Leak detector solenoid/switch connectors
   4. Time delay connector

3. Use cable ties to secure the wire harness to the main wire harness and frame members away from any hot or moving parts (for diesel model only).

4. Remove the plug on the console arm panel and insert the indicator light.

5. Connect the indicator-light connector to the main wire harness (gasoline model only) or to the kit wire harness (diesel model only).

6. Install the audio alarm into the console arm frame (Figure 2).

   

   Figure 2

   1. Console arm frame
   2. Audio alarm
   3. Threaded ring

7. Connect the audio alarm to the main wire harness (gasoline model only) or to the kit wire harness (diesel model only).

8. If your machine is equipped with an overflow hose, loosen the worm-drive clamps and remove the overflow hose (Figure 3).

   Note: Discard the overflow hose and worm-drive clamps.

   

   Figure 3

   1. Worm-drive clamp
   2. Overflow hose

9. Remove the 4 bolts, washers, spacers, and rubber washers that secure the tank cover to the main hydraulic tank.

   Note: Save the bolts, spacers, and washers for securing the leak detector tank to the main hydraulic tank later.

10. Remove the tank cover from the main hydraulic tank.

11. Remove the plug from the hydraulic tank (if equipped); refer to Figure 4.

    

    Figure 4

    1. Plug
    2. Spout

12. Insert the spout into the rubber grommet (Figure 4).

Parts needed for this procedure:

1. Find the appropriate oil-level cover for your machine from loose parts.

   There are 2 different oil-level covers in the kit, 1 for gasoline machines and the other for diesel machines. The cover for the diesel machine is longer than the cover for the gasoline machine and may have a “D etched in it.

2. Use the screw (5/8 inch) and locknut to install the delay timer on the oil-level cover (diesel model only); refer to Figure 5.

   

   Figure 5

   1. Locknut
   2. Delay timer
   3. Screw (5/8 inch)
   4. Oil level cover
   5. Main hydraulic tank

3. Set the oil-level cover in place, but do not secure it to the main hydraulic tank yet (Figure 5).

4. Install 2 hydraulic fittings (90°) onto the front and back of the solenoid valve (Figure 6).

   Note: Position the 90° hydraulic fittings so that the hoses that attach to them are parallel to the ground when installed.

   

   Figure 6

   1. Solenoid valve
   2. 90° hydraulic fittings (2)

5. Install the 90° beaded hydraulic fitting to the main hydraulic tank (Figure 7).

   

   Figure 7

   1. Insert the 90° beaded hydraulic fitting here.
   2. Shield bracket
   3. Hex-head bolt
   4. Oil level cover
   5. Solenoid valve assembly

6. Install 1 end of the tank valve hose to the 90° hydraulic fitting connected to the front of the solenoid valve with a worm-drive clamp.

7. Slip a worm-drive clamp over the other end of the tank valve hose.

8. Connect the free end of the tank valve hose onto the 90° beaded hydraulic fitting on the main hydraulic tank as you lower the solenoid-valve assembly onto the oil-level cover.

9. Install the oil-level cover and solenoid-valve assembly to the main hydraulic tank with 2 hex-head bolts and the shield bracket (Figure 5).

   Note: Before installing the bolts, coat the bottom 2 or 3 threads with anti-seize compound.

10. Torque the bolts to 3 to 7 N∙m (30 to 60 in-lb).

11. Secure the tank-valve-hose end onto the 90° beaded hydraulic fitting with the worm-drive clamp.

12. Install the straight hydraulic fitting into the opening on the underside of the leak detector tank (Figure 8).

    

    Figure 8

    1. Straight hydraulic fitting
    2. Leak detector tank

13. Secure 1 end of the valve hose to the 90° hydraulic fitting connected to the back of the solenoid valve with a worm-drive clamp.

14. Slip a worm-drive clamp over the free end of the valve hose, and secure the end of the valve hose to the straight hydraulic fitting on the leak detector tank.

15. Use 2 worm-drive clamps to secure the overflow hose to the leak detector tank and the hydraulic tank (Figure 3).

16. Connect the delay time connector to the connector on the wire harness (diesel model only).

17. Connect the solenoid valve connector to the connector marked “Leak Detector Solenoid on the wire harness.

18. Remove the plug from the main hydraulic tank (Figure 9).

    

    Figure 9

    1. Remove plug from main hydraulic tank here.
    2. Indicator arrow on nut (2)

19. Slide the O-ring onto the hydraulic-oil-level sensor and install the sensor into the hydraulic tank (Figure 9).

    Important: Ensure that the indicator arrow on each side of the nut that secures the hydraulic oil level sensor points downward (Figure 9).

20. Connect the oil-level sensor connector to the connector marked “Leak Detector Switch on the wire harness.

21. Secure the leak detector tank onto the main hydraulic tank with the 4 bolts, washers, spacers, and rubber washers that you previously removed.

22. Torque the bolts to 3.4 to 6.7 N∙m (30 to 60 in-lb).

23. Ensure that all the fittings are tight.

Parts needed for this procedure:

1. Remove and discard the breather and top off the main hydraulic tank with hydraulic fluid (Figure 10).

   

   Figure 10

   1. Plug (replaces the breather)
   2. Fill with hydraulic fluid to top off the main hydraulic tank here.
   3. Sight window

2. Install a plug in place of the breather (Figure 10).

3. Trim the dipstick to the marked trim line shown in Figure 11. Ensure that the trimmed end is smooth; deburr the end as needed.

   

   Figure 11

   1. 9.5 cm (3-3/4 inches)
   2. Trim the dipstick here.
   3. Appropriate hydraulic fluid level

4. Fill the leak detector tank according to the characteristics of your leak detector tank, as follows:

   • If your leak detector tank has a sight window:

     Fill the leak detector tank with hydraulic fluid until the fluid level is at the middle of the sight window.

   • If your leak detector tank does not have a sight window:

     Fill the leak detector tank with hydraulic fluid until the fluid level is at the middle of the fill marks on the dipstick; refer to Figure 11.

5. Install the dipstick on the leak detector tank (Figure 12).

   

   Figure 12

   1. Dipstick
   2. Leak detector tank

6. Install the console arm cover using the hex-head screws that you previously removed.

7. Connect the battery; refer to your machine Operator’s Manual.