Product Guidelines

Engineer Name :…………………………………………………………..

BULL Cont No:-……………………………………………………

SKID STEER AV490

BULL Machines (p) ltd

SF NO 41, Kangeyampalayam post,
Trichy Road, Tamilnadu,
Date: …………………..
TECHNICAL DATA
 SSL - ENGINE OIL SERVICE PROCEDURE
Engine Oil 15W 40 – 9.5 letter
# Check the new Oil and filter as per Service Remainder,
# Run the Engine for 5 Minutes, Remove the oil filter with the
# Secure the Skid Steer in Flat, use boom and Cabin Safety Lock and Pin oil filter wrench.
Step 1:- Drain the Old Oil, Remove the Oil sump Plug, Clean the drain plug .
Never use an adjustable wrench on the drain plug. Use the properly sized box /
Ring Spanner. Inspect the filter to make
sure the rubber seal / O ring
Step 2:- Remove the oil filter and Fuel Filter, Remove the old oil filter with help (A &B) is not stuck to the oil
of filter Wring, and make sure the rubber gasket comes with it. If not, Remove it filter seating surface of the
from the engine. And clean the Filter Compartment engine.
Inspect the filter to make sure
Step 3:- Place the new Oil Filter, Lubricate the O ring with the new engine oil the rubber seal / O ring (A &B)
(Fuel & Engine Oil Filters),Always hand-tighten the filter. Never use a filter Seats, Add Oil Drop on the
wrench. For engine Oil Filter Rubber seal / O ring

Step 4:- Add New oil, Use a Funnel filling your engine oil, you can also use the DIP STICK ENGINE OIL
dipstick to have an idea of level, Check the engine oil level @ Correct FILTER
Step 5:- Start Your Engine and let it few minutes, Check for any leak, if there are,
you need to turn off the Engine, And tighten that part where leak was seen. Start
the engine Check it after confirm no leak found, turn off the engine
Step 6:- Check the Engine Oil Level , Allow it to Cool for 5 minutes or so. Next
check the oil level via oil dipstick MIN / MAX markings on the level
Step 7:- Place The Fuel Filter – -Ref Page 15
After the rubber seal seats, tighten the oil filter clockwise. Tightening Torque: 12 Nm
**Always Hand-tighten the Engine Oil filter. Never use a filter wrench
OIL DRAIN PLUG.
SSL- AV490 Water Separator - Maintenance

O ring

Filter element

 Remove the top cap, and rinse the inside with diesel fuel. (A) "ON“
(B) "OFF"
 Take out the element, and rinse it with diesel. Spring
 After cleaning, reinstall the fuel filter, keeping out of dust
and dirt.
O ring
 Air-bleed the injection pump.

Filter bowl

Screw ring
(1) Fuel lever
(2) Fuel filter pot
SSL- AV490 Hydraulic System Maintenance
Hydraulic Maintenance - Parking Position
Bull recommended oil: B Oil – 50 Liters
Checking & Adding Fluid : Park on level ground Lower the Lift arms and tilt the
Bucket tach fully back, Check the HYDRAULIC oil Level in the Gauge (Level to the
center of the sight gauge)
If need remove the Hyd Oil Tank Cap (Cap is a Breather)
Add fluid as needed to bring the level to the center of the sight gauge, Install the
fill cap

Replace the Hydraulic Oil & Filters

Replace the fluid As per Recommended due hrs/days, Always replace the hydraulic
charge filter & Suction Filter whenever the hydraulic fluid is replaced.

 Stop the loader on a level surface, lower the lift arms and tilt the Bucket fully
back.
 Remove the Hyd cap/ Breather & Drain plug, and drain the Oil
 Dispose of the used fluid in an environmentally safe manner.
 Tighten the Drain Plug
 Removing And Replacing Hydraulic charge Filter
 Remove And Replacing the Hyd Suction Filter
 Adding Hyd Fluid as per Recommended,
 Start the engine and operate the loader hydraulic controls.
 Stop the engine and check for leaks at the filter.
 Check the fluid level, and add as needed. Suction Filter
 Remove the hydraulic breather cap, Install new breather cap. @Every 500 hrs
 SSL- AV490 CHAIN CASE Maintenance – Oil service

Bull recommended oil: SAE 15 w 40 Chain Case Oil LH (10 Ltrs) & RH( 10 Ltrs)
Check chain case oil
 Place the machine at maintenance position.
 Remove the check plug from the chain case cover.
 Check the oil level through the hole (Check plug).
 If the level is low,
 Must be top up - Remove the bolts for top cover,
 Add new oil as Required, With Help of a funnel,
 Install and tighten the check plug & Top Cover & Packing and make sure
the gasket is good,
Top Cover
Change the Chain Case Oil at every 1000 Hrs Top Cover Packing
1. Remove the Oil Level check plug & Drain plug from the chain case,
2. Remove the inspection cover plate & Remove the bolts for top cover plate
& clean it
3. Check the Drive Chain & Housing Interior and Clean with help of couth
4. Assemble the Inspection cover plate & Install and tighten the Drain Plug,
5. Use a Funnel for your SAE 15 w 40 Chain case oil filling,
6. Check the oil level @ Correct
7. Install and tighten the check plug, Top Cover & Packing and make sure the
gasket is New,
Use the properly sized box / Ring Spanner.
Tools Required : 30-32,10-11 Inspection Plate
 SSL- AV490 CHAIN CASE Maintenance – Chain Tension Adjustment

Bull recommended oil:15 w 40 oil -LH (10 Ltrs) & RH(10 Ltrs)
Place the machine at maintenance position.
 When the Chain Case is in cool condition, Remove the Inspection Plate
 Thumb pressure to Chain between the Sprocket.
 If the Chain is sagging too much,
 Lift the Loader help of Jack stand
 Loosen and remove the Wheel, & Hub mounting bolts and shift the Hub,
 There will be 14mm movement of wheel hub to adjust the chain tension.
Now fine tune as per chain tension less than 5mm
 Tighten the wheel hub mounting bolts.
 Check the two sides of the machine’s chain sprocket. (LH front, LH Rear,
RH front, RH Rear)
 Check / Tighten the bolts for the wheel hub.
 Install and tighten the check plug & Top Cover & Packing and make sure
the gasket is good,
 Tool Required :Wheel spanner,30-32,24,10-11& 2.5 ton jack
 SSL- AV490 CHAIN CASE Maintenance - Wheel Hub
 Place the machine at flat level surface
 Lift the Loader with help of help of hydraulic Jack stand
 Rotate the wheel. Check that the wheel rotates freely and smoothly. Listen and feel for any signs of rough
bearing operation or vibration
 Place your hand on the top of the tire and use a bar to lift the bottom of the tire to check for loose bearings
or "chucking" . If excess movement or "chucking" is found, wheel end service is required
 Remove the tyre / wheel assembly. & Remove the top cover plate, and Drain the chain case Oil
 Remove the hub mounting bolt and washer from the Hub. & move to loosen the chain
 To loosen the axle mounting bolt and spacer,
 Separate the Sprocket from Axle milling LUBRICANT PLUG hole
 Remove the Axle from Hub assy, Remove the Bearing & seal from hub, OUTER BEARING
 Clean the Hub & Axle for seal & Bearing seating area, Seal
 Check for loose, damaged at Seal & Bearing seating area, If any damage please change the new part
 Lubricate the outer bearing cone with the same lubricant used in the hub and install it into the outer
bearing, Spacer
 Install the new seal and check then place the seal end down
 Check to be certain the seal is not cocked and that the seal inner diameter and the bearing turn freely. Spacer
 Lubricate the inner diameter of the seal with a light film of the same lubricant as will be used in the hub.
INNER BEARING
 Then Install the step spacer with the flat end down, then install the inner bearing con inner side of the hub,
 Install the outer bearing in rear side of the hub
 Lubricate the Axle shaft and install the spacer with the tapered end down,
 install the axle in wheel hub,
 Install the bearing on front side of the hub
 Install the sprocket and check/calculate the space (gap), add the spacer as required, Tighten the bolt, as per
recommended pre load (3 to 4 kg)
 Install the wheel Hub apply torque with washer, after the Drive Chain
 Tighten the drive chain, Fill the Oil as recommended -Ref Page 19 & 9
 Check for any leakage, after confirm no leak found assemble the wheel / tyre assembly
 And remove the jack from machine
 Tool Required :Wheel spanner,30-32,24,10-11& 2.5 ton jack
SSL- AV490 Hydraulic Loader Value – Loader Joy Stick Hose Routings

4 – Loader Valve

1 – Loader Valve
Bucket Close

Bucket Open

T – Tank Line
Loader Arm Open
2 – Loader Valve Loader Arm Close

3 – Loader Valve
P - Pump

P – From Loader Pump

MRV @ 230 BAR

1 – From Loader Joystick Port 1
Required Tools
AC – To Arm Cylinder Close
AO – To Arm Cylinder Open
12-- 18- 20- 30- 36- 12--
2 – From Loader Joystick Port 2
4mm
3 – From Loader Joystick 13 19 22 32 41 13
Port 3
Allen
BC – To Bucket Cylinder Close D/E Rings
BO – To Bucket Cylinder 1 2 2 2 2 1 key 1
Open

T – To Hyd Cooler
4 – From Loader Joystick
Port 4
 Hydraulics Pump To Traction Joy stick, LH & RH Drive Motor
SSL- AV490 Hose Routings

Traction Joystick- port1 (4) Pump1

(1) Pump2

(A) RH Drive Motor-1 Tank pipeline

(2) Pump1
(B) RH Drive Motor-2
Traction Joystick -port2 (3) Pump2
Joystick DCV

Hyd Filter Out (A) P1

(A) LH Drive Motor-1 Tank Line

(B) P2
To DCV DCV
Traction Joystick- port3 LH Drive Motor
Tank pipeline (A) P2
Traction Joystick- port4 Tank Line
Hyd Filter Out (B) P2
Required Tools 20-22 18-19 30-32 36-41 Key – 10mm
(B) LH Drive Motor-2 DCV
D/E
2 no’s 2no’s 2no’s 2no’s RH Drive Motor
SSL- AV490 Hydraulic Filter to Loader Value-Radiator & Traction Pump Hose Routings

From Tank
To Traction Pump
From
Hydraulic
Cooler

Hydraulic Cooler From Hydraulic From Hydraulic

filter to Tandem filter Out
Oil coolers are also known as heat Pump
exchangers. The primary function of the oil
cooler in the hydraulic system is preventing Hydraulic filter
the system from over-temperature. Oil IN
coolers in both closed and open hydraulic
system will pass the hydraulic oil through a
coil or core to reduce the generated heat of
the oil.

Required Tools :

6--7 8--9 12--13 30-32 36-41 T – To

16—17
D/E Hydrauli
1 1 1 2 2 Rings
1 c Cooler
SSL- AV490 Hydraulic – Charge pump Pressure Setting Procedure

Adjustment Screw

Lock Nut
 Check The Charge Pressure ‘C’ With Pressure gauge at Engine Ideal RPM
 If the pressure needed to set the charge pressure 23 bar at idle rpm
 Hold the adjusting screw in place using a Alan key Use a hex wrench to
loosen the locking nut,
 Rotating the adjusting screw clockwise decreases Screw for Increase the C
pressure
 Rotating the adjusting screw anti clockwise increases Screw for decrease
the pressure
 To tight the lock nut as per recommended pressure

TOOLS 4mm 5mm

12--13 Allen 0 to 70
Rings 1 1 Pressure gauge
key
1
 SSL- AV490 Hydraulic - Loader Pump Replacement Procedure

 Make sure that the hydraulic tank is thoroughly cleaned out and that all
contamination is removed. If need
 Replace the Hydraulic Loader pump with O ring
 Check / Refill the hydraulic Oil level (recommend Hydraulic oil)
 Replace the Hydraulic filters
 Connect the hydraulic hose(Suction & Delivery )
 Make sure that the Hydraulic Pump is completely full of oil and purged of
all air before starting the machine.
 Tighten All hose & ensure torque and run machine just enough to operate
 Operate arm up and down on full strokes five times. Reduce the Engine
rpm, Check all the pipe lines & hoses there is any leakages.

Required Tools : 36-41,30-32,18-19.

SSL- AV490 Electrical System - Battery Maintenance

 Clean the battery & battery terminals with hot water

 Tighten the hold-down to prevent the battery from
rattling around.
 Check the battery fluid level and add distilled water
stemp level
 Keep your battery charged to 12.6 volts.
 Remember to reconnect the battery(Petroleum Galley)
properly when you’re finished. Always reconnect the
positive terminal first.
Battery – 90Ah,
BATTERY MAINTENANCE

Vent hole

Cell plate

Distilled water level should be below the vent hole & the
stick given below the vent hole and above the cell plate
ELECTRICAL STICKERS AC CABIN
ELECTRICAL STICKERS NON AC CABIN
 SSL BATTERY CABLES & ROUTINGS

[Link] : SSL000B00774
PART NAME : SSL_BATTERY_CABLE_RED

FROM BATTERY POSITIVE

Connector : BATT TERMINAL

TO STARTER MOTOR
Connector : M10 RINGTONGUE
[Link] : SSL000B00775
PART NAME : SSL_BATTERY_CABLE_BLACK
FROM BATTERY NEGATIVE
Connector : BATT TERMINAL

TO FLYWHEEL BOLT
Connector : RINGTONGUE
[Link] : SSL000B00776
PART NAME : SSL_BATTERY_CABLE_CHASSIS

TO CHASSIS GROUND
Connector : RINGTOUNGUE

FROM FLYWHEEL BOLT

Connector : RINGTONGUE
[Link] : SSL000B00772
PART NAME : SSL_ENGINE_HARNESS

To Chassis left top

FROM TO
Y100 Hold coil

To Rear Door To Joystick

harness
FROM TO
F100 Fuel sensor
X101 Temperature sensor To Pressure
A100 Alternator switches
Alternator B+
ALT B+
(Ring tongue)

To Chassis right top

F-Alt,D107, FROM TO FROM TO

D108,D103 M100 Starter motor solenoid G100 Glow plug
SM B+ Connect ring tongue to SM + GND1 Connect ring tongue to Flywheel bolt
[Link] : SSL000B00772
PART NAME : SSL_ENGINE_HARNESS
To Joystick harness To Rear door
FROM TO FROM TO
X3A,X7A,X17A, X3,X7,X17, L106 Tail lamp RH
X12A,PE3 X12, PE3A
L105 Tail lamp LH
To Chassis left top L110 Number plate lamp

FROM TO RC100 Reverse camera

RB100 Reverse buzzer
L104 Rear wok lamp RH
L102 To head lamp harness
IMP1 Implement Hyd1 harness

To Chassis right top

FROM TO
L103 Rear wok lamp LH
L101 To head lamp harness
[Link] : SSL000B00772
PART NAME : SSL_ENGINE_HARNESS

To Pressure switches

FROM TO
Pressure
PS1
switch 1

FROM TO
Pressure
PS2
switch 2
 [Link] : SSL000B00773
PART NAME : SSL_JOYSTICK_HARNESS

To Engine harness
To Relay harness cabin
To Roof harness RH

To Roof harness LH

Y103 – Creeper valve

FROM TO
To Relay harness
Chassis H100 Horn
Y101 DC valve(parking brake)
Y102 Aux valve
[Link] : SSL000B00773
PART NAME : SSL_JOYSTICK_HARNESS

To Relay harness Chassis To Roof harness LH

FROM TO FROM TO
PE1A.PE2A,X1A PE1,PE2,X1 X8,X9,X4 X8A,X9A,X4A
Fuel sensor & Temperature
AC-1, AC-2 To Roof harness RH
convertor
Mount the ring tongue FROM TO
GND1
inside Relay box chassis X5,X15 X5A,X15A

To Relay harness Cabin OTHER ITEMS REQUIRED

FROM TO PART NO DESCRIPTION QTY CONNECTIONS
X10,X11,X13, PE4A,PE5A,X10A,X11A, 5 pin relay 1 K17
PE4,PE5 X13A

To Engine harness
FROM TO
X3,X7,X17,X12,
X3A,X7A,X17,X12,PE3
PE3A
CABIN ACCESORIES AND SWITCHES
 CABIN ACCESORIES AND SWITCHES
Indication Indication
Function Name Function Name
Number Number

1 Audio Speaker RH 11 Head light switch

2 Music player 12 Front work lamp switch
3 Audio Speaker LH 13 Rear work lamp switch
4 Ignition Key 14 Parking break switch
5 Cabin Lamp 15 Hazard switch
6 Aux Switch 1 16 Wiper Switch
7 On / Off Switch 17 wiper washer switch

Creeper Switch / Anti Stall

8 Switch 18 Ac control panel
9 Beacon Switch 19 Glow plug indication switch
10 Glow plug Switch 20 Cluster
HOSE ASSY - STANDARD
HOSE ASSY - WITH IMPLEMENTS
HOSE ASSY - WITH SELF LEVELING BLOCK
HOSE ASSY - WITH IMPLEMENTS AND SELF LEVELING BLOCK
HOSE ASSY - WITH IMPLEMENTS AND SELF LEVELING BLOCKWITH ANTI STALL KIT