Hydraulic Oil Cooler

John Deere 332 Skid Steer

Assembly Instructions (Originating w/Serial Number 50-101)

Model Number: _________________ Serial Number: __________________ Date of Purchase: ________________ Specialized Equipment, Inc.

650 So. Main Street - PO Box 337 - Hector, MN 55342 Business Phone: 320-848-6266 * Fax: 320-848-6269 * Toll Free: 1-800-828-7624

N14880 June 2007

WARNING

Because of the potential safety hazard to eyes from hydraulic leaks and/or flying debris, “USE OF PROTECTIVE EYEWEAR IS ABSOLUTELY MANDATORY” for operator and others in the work area.

Due to the possible danger of flying debris, it is “ABSOLUTELY MANDATORY that IMPACT-RESISTANT SHIELDING” be provided on the power unit to protect the operator. The owner is responsible for providing the operator protection devices on the power unit.

Flying debris can gather on the skid-steer and needs to be cleaned off, especially around the radiator and oil cooler screens, engine compartment and exhaust areas. Periodic cleaning will help prevent the possibility of fire.

TABLE OF CONTENTS

(LOFTNESS OIL COOLER ON JOHN DEERE 332) Page Preparing to Install……………………………………… 1 Installing the Cooler Mount…………………………….. 2 Attaching the Cooler…………………………………….. 4 Preparing to Connect the Hydraulics………………….. 5 Disconnecting the Door Cooler………………………… 6 Connecting the New Inlet Hose………………………… 8 Connecting the New Outlet Hose………………………. 8 Installing the Fan Wire Harness………………………… 10 Check and Verify Operation…………………………….. 11 Cleaning the Cooler……………………………………… 12 Operation…………………………………………………. 13 Cooler Parts List………………………………………….. 15 Oil Cooler Parts Identification…………………………… 16 Mount Kit Parts Identification……………………………. 17

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PREPARING TO INSTALL: 1. The oil cooler shown in it’s shipping configuration.

2. Remove top half of crate. The cooler box is temporarily assembled to the mount base with four bolts for shipping. Unbolt the four bolts to separate the cooler box from the mount base. Unscrew mount base from wood skid. Open cardboard box to locate the remaining parts.

3. Before you begin the installation, make sure you have all the parts as shown (see also pages 14-17). Refer often to pages 14-17 for parts identification and assembly. The oil cooler and protective box (shown).

4. The mounting kit.

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5. The hydraulic kit including hoses and fittings.

6. Prepare the work area and skid steer. Your work area should allow you to raise and lock the boom arms on the skid steer. Make sure the skid steer will not have to be moved. During installation the hydraulics will be disconnected. An overhead hoist is recommended.

INSTALLING THE COOLER MOUNT: 7. Prepare skid steer roof for mounting. Clean the roof surface of excess dirt and debris.

8. Place mount on skid steer roof as shown.

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9. At the back of the cab roof, insert U-bolt around cab pivot lug and up into the slots on the mount as shown. It may be necessary to push down on the mount to allow the U-bolts to stick through the mount holes. Attach 3/8 locknuts and flat washers to U-bolts. Do not tighten hardware until all parts and hardware are in place. Repeat for opposite side.

10. At the front of the cab roof, insert ½ x1-1/2 bolts from top into mount holes and through slots in roof. The front edge of the mount should almost be flush with the front edge of the cab roof, just above the headlight. Loosen rear U-bolts to slide mount forward if necessary. If the mount is too far towards the rear, the cab will not raise completely. Repeat for opposite side.

11. Attach loose bar underneath roof slots with bolts from above. Hold loose bar in place with ½ locknuts. Do not tighten hardware completely until all parts are in place.

12. Cooler mount shown bolted in place.

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ATTACHING THE COOLER

13. Slide bottom screen completely out of cooler box to prevent damage to screen. Use two straps to attached cooler box to overhead hoist. The cooler weighs 220 lbs. Raise the cooler slightly off the ground with the hoist and make sure the cooler and straps are secure.

14. With cooler securely attached to hoist, raise cooler to skid steer roof level and position over the mounts. Note: The hydraulic ports will face towards the rear of the skid steer.

15. Attach legs of cooler box to outside of mount ears using ½ x 1-1/2 bolts and locknuts. Attach all four corners of cooler to mount. The hydraulic ports will face towards the rear of the skid steer.

16. Tighten all mounting hardware.

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17. Raise loader arms. Engage arm lock and rest arms against lock. Raise cab and check clearances for cab, cooler and mount. Lower cab and adjust mounting if necessary. Recheck clearances. Lower and lock cab in the down position when complete. Keep arms raised and locked.

PREPARING TO CONNECT THE HYRDRAULICS: 18. This next section will include routing the hoses, disconnection and reconnecting the hydraulics. Make sure skid steer will not have to be started or moved Disconnect battery for safety. Keep arms in the raised and locked position.

19. The best hose routing is through the shroud of the air conditioning unit behind the cab as shown. Several holes will need to be cut into the sheetmetal shroud to accomplish this hose routing.

20. The hose routing will continue through the air conditioning unit down into the engine compartment following the air conditioning hoses as shown.

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21. Unbolt the top half of the rear air conditioning shroud. Disconnect the tail lights. Remove the top shroud.

22. Top air conditioning shroud removed with slot added to upper right corner for hoses.

23. Close-up view of the top air conditioning shroud removed with slot added for hoses. The 1-3/4” Dia x 3” Slot is centered 4” from the right side and 1-1/2” down from the top. Line the newly cut sheet metal edge with rubber edging.

24. A similar hole (as cut in the top shroud) should be cut into the bottom shroud of the air conditioning housing. The two holes should align with each other. Note: Use caution not to cut any internal hoses, lines or wires in the air conditioning unit. Line the newly cut sheet metal edge with rubber edging.

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25. In the sheet metal behind the cab on the right side, cut notch to accommodate two 1-7/16” Dia hoses (as shown). Note: Use caution not to cut any hoses, lines or wires. Line the newly cut sheet metal edge with rubber edging.

DISCONNECTING THE DOOR COOLER: 26. Open rear engine door of skid steer. Remove skid steer hydraulic tank hose (2nd hose next to door). The hydraulic tank hose (2nd hose) connects the door cooler to the hydraulic tank. It may be helpful to disconnect the 1st hose to get access to the tank hose (2nd hose).

27. Hydraulic tank hose shown removed at door end (2nd hose).

28. Hydraulic tank hose shown removed at tank end, next to battery behind the right rear access panel. Plug fitting temporarily to keep hydraulic fluid from escaping.

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CONNECTING THE NEW INLET HOSE: 29. The inlet hose (144”) will run from the door-cooler to the inlet port on the roof-cooler. The 144” hose has two different ends. a. Roof cooler: JIC-16 (1-5/16 Dia) Female Swivel b. Door cooler: Flat Face-12 (1-1/16 Dia) Female Swivel

30. The new inlet hose (144”) shown attached to the door cooler (Flat Face-12 (1-1/16 Dia) Female Swivel).

31. Route the inlet hose (144”) down towards the battery, under the coolant bottle, and back up towards the roof cooler.

32. The inlet hose (144”) will pass through the holes previously cut in the sheet metal on its way to the roof cooler.

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33. Add the 90º fitting to the inlet port on the cooler. Attach the inlet hose (144”) to the 90º fitting as shown. The hoses on the cooler should be looped upwards (as shown) so they do not pinch when the cab is raised up.

CONNECTING THE NEW OUTLET HOSE: 34. Route the outlet hose (96”) from the skid steer tank fitting around the coolant bottle and up towards the roof cooler (see photo).

35. The outlet hose (96”) shown attached to the tank port on the right rear side of the skid steer. If you had installed a plug in the tank port earlier, make sure you remove the plug before connecting the outlet hose (96”). The 96” hose has two different ends. a. Roof cooler: JIC-16 (1-5/16 Dia) Female Swivel b. Tank Port: Flat Face-16 (1-7/16 Dia) Female Swivel

36. The outlet hose (96”) will pass through the holes previously cut in the sheet metal on its way to the roof cooler.

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37. Add the 45º fitting to the outlet port on the cooler. Attach the outlet hose (96”) to the 45º fitting as shown. The hoses on the cooler should be looped upwards (as shown) so they do not pinch when the cab is raised up.

INSTALLING FAN WIRE HARNESS: 38. Run roof cooler fan wire bundle between cab and back support as shown. An alternative would be to run the fan wire bundle down with the hoses if there is room in the cut slots.

39. Run the fan wire bundle along the back of the cab as shown.

40. Inside the engine compartment, run the roof fan wire bundle from right to left, along the top-back with the other wire bundles.

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41. Yellow Wire (Cooler) = On/Off Switched Red Wire (Cooler) = Power Black Wire (Cooler) = Ground Splice the yellow wire (Cooler) into the red/orange wire from the engine hood fan (shown). Protect the yellow wire (Cooler) with an inline 5 amp fuse/holder. The red and black wires (Cooler) will continue down to the alternator.

42. Red Wire (Cooler) = Power Black Wire (Cooler) = Ground The black and red wires (Cooler) will continue down the left side of the engine compartment to the alternator.

43. Red Wire (Cooler) = Power Black Wire (Cooler) = Ground Attach the red wire (Cooler) for power as shown. Protect the red wire with an inline 30 amp fuse/holder. Attach the black wire (Cooler) for ground as shown.

CHECK & VERIFY OPERATION:

44. To verify the fan operation, the temp sensor must be by-passed. By-pass the temp sensor by disconnecting it from the green wires of the control box. Reconnect the two green wires (control box) into each other to form a loop.

Reconnect the battery. Turn on the ignition key without starting the engine.

The roof cooler fan should start after a 30 second delay if the temp sensor is by-passed.

Turn ignition switch off. Reconnect the temp sensor.

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45. Raise cab and check that the hoses from the roof cooler do not pinch against the cab structure.

46. Recheck all the hydraulic connections. Start engine and function loader arms slowly. Unlock safety lever & lower loader arms to ground. Carefully observe for any hydraulic leaks. Caution: Do not use exposed skin to test for hydraulic leaks. High pressure oil can be injected into the skin. If oil is injected into the skin, seek immediate medical attention as serious side affects and death can occur.

CLEANING THE COOLER: 47. The bottom screen pulls out for easy cleaning.

48. The top unbolts for access to the fan, fan controller, temperature sensor, check valve and cooler core.

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49. The fan and shroud top pivot up for access to the cooler core fins. When cleaning the cooler core, be careful not to bend over the small cooler fins as this will severely affect the cooling capacity. Low pressure water or high pressure air can be used with caution. High pressure water is not recommended.

OPERATION: 50. In typical operation, the temp sensor will turn the fan on when the hydraulic oil temperature reaches 140ºF. Once the fan is operating, it will run for 30 seconds in the reverse direction blowing air down and cleaning off the lower screen. After 30 seconds the fan will stop, pause and change direction. Next the fan will run for 10 minutes in the forward direction blowing air up and out through the top. The fan will repeat this cycle every 10 minutes. The temp sensor will turn the fan off if the hydraulic oil falls below 130-125ºF.