Power Steering & FEL on Yanmar F16 project

[jimmer2880]

Here's the start of my project to add a Koyker 80 FEL and Power Steering to my Yanmar F16d.

The Koyker 80 doesn't have a mounting kit for my F16, so I'll be making my own.

While I'm doing that, I'm also adding power steering. Again, no kit was available. However, I can't say enough about the help I got from Rick at Tractor power steering conversion kit and parts store.

First step, Remove the skins.

Now, disconnect the decompression and fuel shut-off cables

http://i76.photobucket.com/albums/j7/jimmer2880/Yanmar_Project/IMG_3038.jpg

 

[jimmer2880]

I'll be replacing the steering column, so off with the old.

Here's a close-up of a bracket I'll have to re-make

I'll have to make a plate to cover the trans where the old steering column bolted to

So... that's how you get to the clutch

And finally, the column on the floor

 

[jimmer2880]

The new plate to cover the trans, where the PS orbital hand pump brackets will be fastened. For this, I used 1/2" plate I had laying around

The new steering column bracket (Still need to cut the 1.5" hole for the new column)

The new column sitting in the hole. The new column is ~5" taller than the old. But, since the old wheel was pretty low, it shouldn't matter much.

Also, it looks like I'm going to have to move the fuel tank a little to the front. I am going to move the top to the front side of the mounts, which should give me 1/4 inch. I'm going to move the bottom to the front side of the mounts, and possibly add a 1/4" spacer for a total of 1/2". Hopefully that will be enough.

 

[jimmer2880]

Installed the #6 BPP drain plug (3/8 British Pipe Parallel)

Here are the Input & Output plugs from the factory 3pt spool. I also inserted a 1/4" BPT (British Pipe Tapered) headless plug in the Out port to divert the flow out to the PS & FEL before coming back to the 3pt.

In this pic, the Out port is gold colored. The in port, is silver colored.

That's it for this week. Still need to get the fittings for the PS hand pump before I can make the brackets to mount it. I can't fabricate the brackets for the double acting power steering cylinder until I have the FEL brackets made. I will probably incorporate the PS cylinder brackets into the FEL brackets. Also, I have a 60" woods MMM that will be utilizing the FEL brackets.

 

[Ductape]

Jimmer, keep us posted ! PS is one thing i truely wish my ole tractor had. Also glad to see you have figured out the good way to tap into your hydraulics !

 

[jimmer2880]

I haven't taken the pic's, but I was able to move the fuel tank to the opposite side of the brackets. That bought me another 3/8 to 1/2" of clearance. That little bit appears to be enough. However, I haven't been able to spend any real time in the garage since then.

My Koyker 80 just arrived last night. It sure looks purdy. Hopefully I'll get enough shop time in over the weekend to work on the mounting brackets (which will probably include brackets for the PS cyilinder also).

Unfortunately, the 90deg fittings haven't arrived for the steering column yet, so I can't start to fabricate the base bracket for that until they arrive.

On top of all of that, both of the batteries for my digital camera have decided to go bad. We do have another camera, but I have to wrestle it away from my wife who isn't very keen on allowing the "good camera" inside of the garage. I have no idea why she may feel that way

It's going to be a slow process.

 

[jimmer2880]

I have a question on hydraulic fittings in general.

It looks to me, like the Inside Diamater of a pipe fitting is much larger than the ID of a JIC fitting of the same size. What I mean is, the ID of a 1/4" NPT (or BPP, BPT, ORFS etc) looks to be siginificantly larger than the ID of a 1/4" JIC.

I have been getting all of my fittings with whatever they are on the object to a JIC fitting. that way I will have standard, easy to come by hoses. But, after looking at the small ID of JIC fittings, I'm tempted to go to the next size larger JIC. For example, instead of putting 3/8" JIC fittings on a 3/8" hose, I'm tempted to put 1/2" JIC on 3/8" hose.

Does anyone have any thoughts on that?

 

[Kays Supply]

FYI, check to see if you can get the valve cover off after you move the tank. I had one model that had to be split at the bell housing to get the valve cover off. I would at least check the valve clearances before putting it back together.

 

[jimmer2880]

Kays, Thank you for that pointer. I just looked. My F16 has what I would consider a mini-firewall (piece of sheet-metal) between the engine compartment & where the fuel tank is located. There's a good 1.5" between that & the fuel tank. The valve cover is even further forward. So, plenty of room there.

Thanks again though.... I hadn't thought of that, so I'm glad you said something.

 

[jimmer2880]

Update: I only got to work on it a couple hours today. But, I have 2 of the 3 steering column brackets painted & ready to go. Everything on the column is now located though. I need to get some o-rings for the ports on the bottom of the column before I can do the final fit-up.

The double-acting cylinder for the PS is placed as well. I hope to make the mounting bracket for that tomorrow. I was unable to use the mounting bracket for the FEL, but I will be able to tie it into the steering column bracket. Unfortunately, I'll need to notch out the sheet metal on the left-side skin to accomodate the bracket.

I was able to locate the Priority valve under the battery box behind the seat.

The loader is located around the tractor. Now, I just have to make the mounting brackets.

On the F16, there are 2 sheet-metal & clear plastic guards that extend towards and up from the front of the foot-rests. I will probably not be able to re-install those, as the FEL brackets and PS cylinder will interfere. But, That's ok, I wasn't that fond of those anyway.

I'll try to snap some pictures tomorrow of my progress.

thank you everyone.

 

[jimmer2880]

Here are the pic's from this weekend's progress.

Here is the completed steering column bracket. All I need to do, is weld the black column to the red pipe once it's installed. The red plate on the bottom will get bolted to the plate on top of the transmission.

Here's the new next to the old.

Here's the almost finished plate on top of the trans. I will be welding a bracket off to the left of it to support the power steering double-acting cylinder. I haven't started that bracket, but it shouldn't be hard. I will need to cut the sheet-metal if it stays permenant. However, I have plans on moving the front axle a couple inches forward next year, so then I'll be able to use the FEL brackets as a mount for the cylinder.

Here is the cylinder laying about where the new bracket will be made.

 

[jimmer2880]

Here's the FEL hanging off of the tractor. I needed a temporary hoist while I got everytihng perfectly located. I was trying to come up with something grand, when my dad said "just use the ladder". I checked, the ladder is rated at 300 lbs. Since the entire FEL only weights 500, and we'll be picking up much less than 1/2 that, I figured why not. I supported the top steps a bit with some angle, then hung a 2-ton chain host from that. worked like a charm. I didn't trust it at all though, as soon as it was in place, I blocked the FEL & removed the tension from the ladder.

 

[jimmer2880]

It is a very tight fit putting the koyker 80 on this F16 while maintaining use of the Mid-mount mower. What is black, came from Koyker. What is red, I built. I ended up putting a 1/2" thick plate, ~4.5" wide across the belly of the tractor. There are 4-unused threaded bolt holes in the belly of the trans. They are the metric equivelant of 1/2" diameter.

That plate, is welded into a vertical piece of 1/2" thick x 4.5" wide x ~6" tall piece of plate. That bracket, looks like an upside-down "L". 2 bolt holes in the top bolt into the same ~.5" diameter metric holes on the side of the Trans. Then, I have 2 more holes on the "L" that the Woods MMM bracket bolts onto.

From there, I took a ~5" long piece of 2x4x3/16 wall box tubing, that I welded a piece of 3"x3/8" flatbar on each side. Welded that between the "L" plate, and the flat plate that Koyker supplied. I would have liked to go with a piece of 4" tubing, or 4" square, but the clearance between brake/clutch pedals and the front wheels while turning. You can see that I actually had to notch the plates from Koyker (still need to clean them up a bit - a torch isn't a pretty thing in my hands )

Here's another from the same side, different angle.

 

[jimmer2880]

Another, same side, different angle

Still another. here, you can see the tan MMM bracket on the left

 

[jimmer2880]

I was also able to bolt the "Priority Flow Diverter" in place. I put it under the battery box in the rear, next to the battery.

I ordered the first couple of hoses and a few more fittings. With any luck, I'll have the rest of the brackets finished next weekend along with some of the preliminary hose plumbing.

I have also updated the hydraulic layout. I found out that the Pressure relief on the priority valve only works on the PS side. So, to protect the tractor pump for the times that I forget to plug the hoses back together when I remove the FEL (at least, that's what I hope will happen. If not, please tell me now )

 

[Ductape]

The white bracket for the belly mower ...... is that for a Woods L59 ???? Looks just like mine !

 

[jimmer2880]

The white bracket for the belly mower ...... is that for a Woods L59 ???? Looks just like mine !

Yes, it is a Woods L59. I love the mower, seems to be very very well built and handles the tall grass like nothing.

 

[jimmer2880]

No pics this time.

The steering column brackets are finished and mounted. I'm happy with the rigidity of it all. I was also able to locate the PS cylinder in front of the foot rest. The end result isn't ideal, but it should work. I'll have to post some pic's and see if anyone has any better ideas.

I was able to get the FEL hanging from the tractor. I still need to work on bolting the front plate onto the front bumper. Also, the FEL valve spool is bolted onto the FEL arm. However, Koyker sent the worng hoses (between the spool & the hard lines on the FEL). They are sending the correct ones, but that's a good 5 day shipping from them. Guess I won't get it running this weekend.

The MMM brackets are also installed and am ready to hang the mower.

I should be finished with the fab work by EOB tomorrow (nice to have Fridays off ). Hopefully my hydraulic lines & fittings will come in from Burden Sales Surplus Center - Hydraulics, Engines, Electrical and More, but I am afraid I won't get that till Monday or Tuesday. I have ordered as much as possible from Discount Hydraulic Hose.com - Your Source for Hose, Fittings and More because they are only 1 day shipping from me. But, their hose prices are much greater than surplus center, and they don't carry valves (I also ordered the pressure relief valve for before the FEL quick connects)

With some luck, I'll have lots of good pic's by the end of the weekend. At the very least, it should be finished by next weekend.

 

[jimmer2880]

The UPS man wasn't good to me today . Neither of my 2 packages arrived.

But, I did get a lot accomplished. The mechanicals of the steering are hooked up and ready to go. I have the hydraulic lines ran on the steering cylinder as well as the feed & return line out of the steering pump.

Also, I re-made the battery tray which is behind the seat. I moved the battery all the way against the left fender, which leaves room for the Priority Valve and pressure relief valve on the right side of the battery box, against the right fender.

The MMM is also hanging from it's newly re-located brackets.

The project is winding down. I'll be attaching the front cross-bar of the FEL to the tractor tomorrow and tightening bolts.

After that, it's down to waiting for hoses & quick connects to arrive. She should be running by next weekend.

 

[DRL]

Jimmer,
Great project. Thanks for all the pixs, great learning tools.
Was studying your hydraulic layout and need some help. In the upper right, blue "hard line from pump", pressure side of pump? Lower left, "transmission plug", return to tank? Am I correct? If so are the "P"(pressure) and "T"(tank) ports on the steering valve switched or am I missing something?
Also are there more line that are not shown on the 3pt valve, I don't understand it.

Thanks, keep up the good work

DRL