—

—

L82U9A4000137

L82U0A4000138

2

University of Colorado - Colorado

L427

—

—

S92U693000027

S92U693000027

1

University of Colorado - Colorado

L428

—

—

S92U893000028

S92U893000028

1

Walt Disney World - Florida

L535

1204

1213

L82UXA4000003

L82U0A4000012

10

Whitehorse - Yukon

L563

38

41

L82U3A3000255

L82U9A3000258

4

Woodstock - Ontario

L460

—

—

L82U693000309

L82U693000309

1

Woodstock - Ontario

L492

—

—

L82U4A3000040

L82U6A3000041

2

PAGE 3 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

WARNING

Follow your internal safety procedures.

PROCEDURE
NOTE

Dirty hydraulic systems can quickly clog a new filter element, making cleanliness vital. It is important to
remove any dust from the external surfaces of the filter assembly, and to plug all piping to prevent any dust
or dirt from entering the system. Hydraulic fluid should always be filtered through at least an ISO 16/13/04
rated filter before the system is topped up with fluid. When the pump, motor, steering gear housing, hydraulic
tank, filter or hydraulic lines have been removed or dismantled for replacement or complete maintenance, the
hydraulic system should be drained before it goes back into operation. It is then recommended to perform
a dialysis.
1.1.

Remove the right rear lower corner panel from the vehicle. Retain the panel and hardware. See Figure 1.

1.2.

Place a container under the hydraulic tank.

1.3.

Remove the drain plug at the bottom of the hydraulic tank. Clean and retain the drain plug. See Figure 1.

1.4.

Drain the hydraulic oil.

1.5.

Install the clean drain plug at the bottom of the hydraulic tank. See Figure 1.

1.6.

Clean the top of the hydraulic tank with a dry, clean, lint-free cloth.

Drain plug

Rear lower
corner panel

Figure 1 - Rear Right Corner Panel and Hydraulic Tank Drain Plug

PAGE 4 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.7.

Install the bulkhead quick connect fitting N64549 on the remote breather N64552. See Figure 2.

1.8.

Affix the bulkhead quick connect fitting N64549 on the remote breather support bracket N64587. See Figure 2.

1.9.

Connect the 1/4'' nylon tube 8860102 on the bulkhead quick connect fitting N64549. See Figure 2.

1.10.

Affix the remote breather support bracket on the rear engine control box left anchor bolt. See Figure 2.

Rear engine control box left anchor bolt

Remote Breather
N64552

Remote breather support
bracket N64587

Bulkhead quick
connect fitting
N64549

1/4 Nylon tube
8860102

Rear engine control box

Figure 2 - Remote Breather Installation

PAGE 5 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.11.

Disconnect the hydraulic hoses from the filter head. Install a clean rag or clean plastic bag at the end of the
disconnected hydraulic hoses. See Figure 3.

1.12.

Disconnect and remove the hydraulic pressure sensor. Retain the pressure sensor. See Figure 3.

1.13.

Loosen the hydraulic T-Fitting.from the filter head.

1.14.

Remove the filter head from the hydraulic tank. Retain the hardware, harness and harness support bracket.
See Figure 3.

1.15.

Remove the hydraulic T-fitting from the head filter. Clean and retain the hydraulic T-fitting.See Figure 3.

1.16.

Remove the hydraulic pressure switch from the filter head. Clean and retain the hydraulic pressure switch.
See Figure 3.

1.17.

Remove the quick disconnect fitting and dust cap from the filter head. Retain the quick disconnect fitting and
dust cap. See Figure 3.

Remove and retain hydraulic
pressure switch, harness and
support bracket from the filter head

Remove filter
head and retain
hardware
Remove and retain
hydraulic T-fitting
from the filter head

Disconnect hoses
from hydraulic T-fitting

Remove and
retain quick
disconnect fitting
and dust cap
from the filter
head.

Figure 3 - Hydraulic Parts to Retain for Filter Head and Installation of New Hose
PAGE 6 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.18.

Install the supplied O-ring on the bottom adapter plate N8905940 (include in the N8905966 kit). See Figure 4.

1.19.

Install the gasket N60839 on the hydraulic tank. See Figure 4.

1.20.

Apply a thin coat of thread sealant on the first thread of the Allen bolts N66029. See Figure 4.

1.21.

Install the bottom adapter plate N8905940 on the hydraulic tank using the the Allen bolts N66029. See Figure 4.

1.22.

Install the quick connect fitting N64545 on the bottom adaptor plate. See Figure 4.

Gasket N60839 installed on the hydraulic tank

O ring installed on the bottom
adaptator N8905940.

Bottom adaptator N8905940 installed on hydraulic tank with Allen
bolt N66029.
Allen bolts N66029 with thread
sealant applied on the first thread.

Quick connect fitting
N64545 installed on
bottom adaptor.

Torque to 12 lb-ft
(16 N•m)

SEALANT

Figure 4 - Bottom Adaptor and Remote Breather Quick Connect Fitting on Hydraulic Tank

PAGE 7 OF 12

INFORMATION LETTER
1.23.

SAV.1E.2012MA

LI3994ER1

Remove the plastic cap at the end of the new filter head N8905938. See Figure 5.

N8905938 New filter head

Remove the plastic from the filter head

Figure 5 - Preparation of the Filter Head

1.24.

Install the supplied O-ring on the top adapter plate N8905940 (included in the N8905966 kit). See Figure 6.

1.25.

Install the top adapter plate N8905940 and the new filter head N8905938 (included in the N8905966 kit) on
top of the bottom adapter using the bolt supplied in kit N8905966. See Figure 6.

1.26.

Install the harness support bracket on one of the filter head bolt. See Figure 6.

1.27.

Apply a thin coat of thread sealant on the new 9409927 elbow fitting and install the fitting on the new 9409939
T-Fitting. See Figure 6.

1.28.

Apply a thin coat of thread sealant on the new 0657590 fitting and install the fitting on the new 9409927
elbow fitting. See Figure 6.

1.29.

Apply a thin coat of thread sealant on the retained hydraulic pressure switch and install the switch at the end
of the 9409939 T-fitting. See Figure 6.

1.30.

Apply a thin coat of thread sealant on the new 9409939 T-fitting and install the T-fitting on the filter head.
See Figure 8.

1.31.

Connect the new 3/8'' nylon tube N17208 on the 0657590 fitting. See Figure 6.

1.32.

Install the new filter N8905939 inside the new filter head N8905938 (both parts are included in the N8905966
kit). See Figure 6.

1.33.

Connect the harness to the hydraulic pressure switch. See Figure 6.

1.34.

Affix the connector to the harness support bracket and secure the harness using a tie wrap. See Figure 6.

1.35.

Cut the excess lenght of the 1/4'' nylon tube 8860102 and connect to the quick connect fitting N64545 installed
on the bottom adaptor. See Figure 6.

PAGE 8 OF 12

SAV.1E.2012MA

LI3994ER1

INFORMATION LETTER

Filter N8905939

Filter head N8905938

3/8 nylon tubing N17208

Hydraulic pressure switch

T-fitting 9409939

Fitting 0657590

Elbow fitting 9409927

Top adaptator N8905940
Connector affixed to
the harness support
and harness secured
with a tie wrap

Torque to 12 lb-ft (16 N•m) to
affix the top adaptor and filter
head on the bottom adaptor.

1/4'' nylon tube
8860102 connect to
the quick connect
fitting N64545

Figure 6 - Filter Head N8905938 and fittings Installed

PAGE 9 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.36.

Apply a thin coat of O ring lubricant on the ORS O-ring N8885935 and the ORFS O-rings 507303.

1.37.

Install the ORS O ring N8885935 and the ORFS O-ring 507303. See Figure 7.

1.38.

Install the retained hydraulic T-Fitting on the new filter head. See Figure 7.

1.39.

Connect the hydraulic hose disconnected at step 1.11, to the hydraulic T-fitting on the filter head. See Figure 7
for torque value.

Install ORFS O-rings 507303 on the
portion of the T-fitting that the hydraulic
hoses will connect.

Torque the hoses to
96 ± 4 lb-ft (130 ± 5 N•m)

Install ORS O ring N8885935 on the
portion of the T-fitting that will connect with
the filter head.

Retained T-fitting installed
on the new filter head

Figure 7 - O ring and Torque Value of the T-fitting

PAGE 10 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.40.

Remove the push button (N30612) from the discharge valve and remove the discharge valve from the support
bracket.Retain the parts. See Figure 8.

1.41.

Install a hose clamp on the coolant filling hose.

1.42.

Remove the coolant quick connect fitting from support bracket. See Figure 8.

1.43.

Remove the support bracket from the frame. Retain the hardware. See Figure 8.

1.44.

Install the new N79775 dual bracket on the frame using the retained hardware. See Figure 8.

1.45.

Affix the removed quick connect fitting and discharge valve in the top holes of the new plate N79775. See
Figure 8.

1.46.

Install the push button (N30612) on the discharge valve.

1.47.

Install the new T0647 bulkhead fitting in the bottom left hole of the new plate N79775. See Figure 8.

1.48.

Install the new 0443990 reducer fitting on the T0647 bulkhead fitting. See Figure 8.

1.49.

Install the retained quick disconnect fitting and dustcap on the 0443990 reducer fitting. See Figure 8.

1.50.

Install a new 0657592 connector fitting on the back of the bulkhead fitting T0647. See Figure 8.

1.51.

Connect the 3/8'' nylon hose N17208 to the 0657592 connector fitting installed on the new plate N79775.
See Figure 6 and 8.
Actual configuration

New configuration

Discharge
valve

Support bracket to
remove
Coolant quick
connect fitting

Remove and retain the
coolant quick connect
fitting and discharge valve

T0647 Bulkhead fitting,
0443990 Reducer fitting,
0657592 connector and
retained quick disconnect
hydraulic fitting (dust cap)
installed on new N79775 dual
bracket.

Figure 8 - Original Bracket to Remove and New N79775 Dual Bracket Installed
PAGE 11 OF 12

INFORMATION LETTER

SAV.1E.2012MA

LI3994ER1

1.52.

Remove the hose clamp installed on the coolant filling hose.

1.53.

Connect a drum of new hydraulic oil to the quick disconnect fitting located on the new dual bracket.

1.54.

Fill the tank until the level in the sight glass indicates the correct level.

1.55.

Do not disconnect the drum of new hydraulic oil. Start the engine and let it run for 2 minutes in fast idle mode.

1.56.

The fluid will drop significantly; fill the tank until the fluid level indicator show the correct oil level while the
engine is still running in fast idle mode.

1.57.

Turn off the engine and disconnect the drum of hydraulic oil from the quick disconnect fitting.



PAGE 12 OF 12